There will be many instances where you will need to improve the manufacturing operation by making it fast. This can lead to many things. It is usually a response to external stimulus like competition, a quality event or a messed up product launch. It may also happen when the demand increases with no forthcoming caveat from new info or orders from the customer. It may also happen because of failure of internal sales and operations planning (S&OP) process. Or maybe, the manufacturing department has faced major deviation and someone new messes the status quo. No matter what the reason, you can take the following tips into consideration enlisted by Tervene experts when it comes to increasing the production.
- Aim at the objectives
The gist of lean manufacturing is factory throughput. You can aim at the objectives by the means of Taichii Ohno’s wheel as it delineates classic wastes:
- Over production
- Over processing
In each of these aspects, there are many methods to be looked down upon for improving the results. This makes sense when you prioritize what to fix first. Waiting, inventory and defects are the topmost three targets to work on when improving manufacturing.
- Waiting waste
No matter if it is the machine capacity or the human capital, there is nothing more sinful than being patient for the product to move via the system. If the things aren’t moving ahead, know that either the machines are down or there are missing people, materials and parts. There are many ways to fix these problems. There could also be a case of maintenance and machine downtime, shift loading, or organizational or skill versatility. Missing parts usually lead to supply chain issues like supplier and forecasting management.
- Defects waste
Making defective products lead to a lot of wastage of time, efforts and money as it is fully loaded with labor and material costs. Moreover, we add costs to detect, classify and fix the defects. Quality comes in top three as it cannot suffer in the throughput objective. Nothing destroys the initiative to raise the throughput faster than a quality problem delivered to the customer. It is just not about the cost of addressing the issue that impacts the company the most, it is also about the customer and supplier relationship.