| Topic : Steps in making manufacturing profitable |
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Manufacturing & Engineering Professionals |
Research_Development_Design |
Technical Engineers |
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Activity:
755 views;
last activity : 10 30 2011 07:43:30 +0000
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Quality Management
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Adopt Lean methodology
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Making manufacturing plants more profitable.
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Right Placement
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Choose smartly your profitability strategy
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Design Products and services that fit into customer's social and anthropological system
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By Value Stream mapping
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Good production planning
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Introducing robotics in a high yielding plant to expedite the process
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Rapid Prototyping
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Make manufacturing plant more profitable
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minimize wastage,production cost,n make process more friendly...
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Lata Sharma
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by consulting lower level staff
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Proper management
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Make your own systems based upon the available benchmarks
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TRAINING PROGRAM FOR EMPLOY
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Recovering of waste
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dilbag singh
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Will power and craving of the management gives result
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Adopt Lean Methodology
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Effective process plan
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An organization is what it's people makes it. People's involvement aligned with Business Policy makes an organization profitable
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collaborating multipurpose services in one product
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Materials Management
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Have Clear Process, Planning and strict Implemention
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Decrease the changes as per model wise.
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r k
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Right technology
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Right technology
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Right technology
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Right technology
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Outsource For Better Profits
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skill of the employees
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see it
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Quality Control
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Lean and IT enable your plant.
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Quality Work
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Outsourcing non-core activities and components which are readily available in market
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USE THE RIGHT STRATEGY
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Proper Maintenance,Timing-increase factoring timing,Add new to your manufacturing product
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Proper incentive sceme and multitasking
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Incentive scheme and musltitasking
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continous improvement and well documentation of processes
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A MULTIDIMENSIONAL APPROACH
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Adopt modern production technology
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ALL 5 POINTS TO BE IMPLEMENTED
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REDUCE THE CYCLE TIME
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not a single method can work in every maufacturing unit.
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Stream line knowledge areas
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Quality Management
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Implementation of a quality management program will save money and increase profits. Some popular methods are the Total Quality Management method and the Six Sigma method. The idea is that by reviewing the entire company process, problem spots can be identified and solutions can be created. This allows the company to improve the quality of the products they
produce along with increase the effectiveness of their entire business
process. This entire process results in a more efficient company and
more overall profits.
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top 5 to make the plant more Profitable. 1.Quality Management 2.Follow 3M Policies & Internal Support of Purchase, Qulaity and Production 3.Supplier Control & Supplier Quality 4.Making adaptaion to Plan fluctuation as per Market Strategy. 5.JIT & Inventory Management.
implementing any system is not only sufficient, making it sustain is also a key point to take care. easy adoptable, understandable, less documentation will help any tool to work efficiently, show business is not all the system wants.
I also support quality because Do it right first time every time reduces reworking timings and improve quality of the product ant its brand name ( because productivity increases with increasing demand)and 5s , process capability studies ,reducing absentism and reducing 16 manufacturing losses will make manufacturing more profitable.
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Aadopting Lean manufacturing practices & six sigma approach leads to elimination of waste,improved quality perfomane,reductions in rejections,improved customer satisfsction & hence profis
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It is true that lean manufacturing is helps to make any organisation profitable as Lean works on the concept of continuous elimination of unnecessary, non-value added steps within a process. it is about producing products and services, faster and at a lower cost & to make it more effective the six sigma is used with it as it controls the variation.
The main role of HR increase the gravity of the situation by looking for sectorial candidate. By such methods both the potential organization and the candidate are at loss. Extra care is required for the selection. Organization will make profits if it is having good supply chain management.Both quantity and quality of its products decide the profitability.One should understand the changing needs of the customer, loyality, law of the land and to most possible extent a management with democratic approach to both its customers and to its own employees.
The main role of HR increase the gravity of the situation by looking for sectorial candidate. By such methods both the potential organization and the candidate are at loss. Extra care is required for the selection. Organization will make profits if it is having good supply chain management.Both quantity and quality of its products decide the profitability.One should understand the changing needs of the customer, loyality, law of the land and to most possible extent a management with democratic approach to both its customers and to its own employees.
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It is as complex as finding a single formula for making the manufacturing plant more profitable.But it could be achieved to a great extent by adopting particpative management and making each unit/department a profit center.
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I think there should be meetings held for lower level management rather than higher level management,this will bring awareness among workers,and later the higher mgmt should draw ideas put by lower mgmt,and also by motivating the workers by providing good rewards and promotions,this will increase the enthusiasm among workers,which will lead to reduce in flaws/scraps.which inturn will be profit for the industry.
Any organization will make profits if it is having good supply chain management.Both quantity and quality of its products decide the profitability.above all general theories of profitability, one should understand the changing needs of the customer, loyality, law of the land and to most possible extent a management with democratic approach to both its customers and to its own employees.
Dear sir,
It looks great that we have give support to all maintenance people where we have good rapo and see that keep the machine without break down. Moreover you have to ensure that spare parts are kept in place when machine break down take place you should in position to replace for avoiding times and production.
Prfitable subject to market condition how your product has sold.
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Now a days, Becoming an engineering graduate is much easy, which led the quality to drop down and its difficult to find the right candidate to look for the entire manufacturing process and the role of HR also increase the gravity of the situation by looking for sectorial candidate. By such methods both the potential organization and the candidate are at loss. Extra care is required for the selection. At the same time even the good organizations didnot know what is there requirement. |
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I also agree with shivaram parsad. you give the exact point to be discussed, because these are the basic things u share, I am working in maintenance from past 14 years and reduce the breakdown& machine failure by adopting these techniques.But when it goes to cost they not compare the saving against investment.
Unfortunately maintenance as a concept is mis- represented and mis- understood in most developed countries. In developed countries this is coined as " Asset care" which is more appropriate. The difference is what would be between "Health check up" and "Medication". The terms it self are and positive and negative. Most of the firms have a mind set up of considering as Maintenance department as ca cost drain and could not come to terms as " Good cost" as against other costs as marketing, sales, distribution etc. Result and cause are not visibly related and measured. Most importantly the time lag is huge.
In developed countries, mostly the maintenance is replacement on a regular time intervals and takes precedence over production targets which is exactly being compromised in
Most importantly the 'cost of opportunity lost" Vs cost incurred on the machine in a time duration of 5-6 years also to be considered.
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Just a thing, I wrote this post in summer 2008, and the crisis was not in all minds. The goal was to explain there are others way to make profits than just lean sigma. All profit strategies (mass production, chain production, toyota models, ford models) have been chosen by cars companies, according to the crisis they were facing. Studies about other manufacturing areas are missing, so I just talked about car manufacturers. The following advices are working only for industries similar to car companies in the production plant. which growth system exist in your market? competition for everyone, competition and consumation, competition and exportation, nationaly coordinated productivity based, nationaly coordinated exportation based (specialisation or price), shortage and investissement and to finish annuity and inequality? The growth of your market is: changing with competition, with consumption, with exportation, chaotic (raw material for example), or depending on savings? Which benefit strategy you choose? diversity and flexibility, quality, volume, volume and diversity, innovation and flexibility, constant cost reduction. There is also a "new" benefit profit strategy from England, based on short time profitability due to very powerful institutionnal investors, commonly discuss nowadays. In your market, how is the distribution of income? if depend of opportunism or power, competition environement. If nationaly coordinate, coordinate environement, ... Your market is with hierarchy, exclusion, huge, luxury, closed groups, homogeneous, heterogeneous... Profitability strategy must take care of the growth and distribution system of national income, especially the effects on the market AND the worker IN GENERAL, and of course all the members of your company. Build a company compromise adapted:eg for cost reduction: work if no conceptual innovation, if no huge variation of production, if workers understand effects of cost reduction in employement and salaries. The market must be product centered and with no or very few hierarchy . The compromise must be create with the workers, the chiefs and the suppliers miracle production systems like the lean production are toyota based systems and are the result of IMVP and MIT studies. They encourage the idea that industries in the 20th century have grown in three steps: craft industries then mass production and finally lean production, which is historically false. Even they are full of statistics and sometimes good ideas, this is bullshit if you are using it when the growth system you are living is not entirely free of compels or not socialy accepted. One side effect european companies have seen is the flee of high qualified workers to others company and an incredible raise of vacancy for no reason. Cost reduction seems to work only in two environments: shortage and investissement environment because workers must wait before the rise of their lifestyle and high competition market with workers compelled by price competition .Do not forget cost reduction strategy must be chosen by suppliers too... When finally you will have choose a profitabilty strategy adapted to your market and your environnement, your plant organisation and process will be the origin point, your profitability strategy the end point and everyone will be able to "see" clearly where they are going. Make things clear is important nowadays when nobody knows what tomorrow will be. Offer stability is highly appreciate and counterbalance salary very efficiently. Remember that all this is based on the observation made by Taylor that a good worker has a productivity four times more than a bad worker. One hundred years later, is it really changing? |
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For the success strategy is necessary. If you want to make profit you must have to choose right marketing strategy, production method etc. To choose right strategy first you have to do SWOT & PESTL analysis.
Choose Smartly & Act correctly.
To answer this difficult question, I am writing more precise posts, under the name production models.
Design Products and services that fit into customer's social and anthropological system
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One of the greatest successes for manufacturing process is to fit the product or service to the social and anthropological system. If the product is designed out side India and adopted for ease of manufacturing in India, what ever you be the systems you adopt is likely to fail. Let us consider the most secretive company in the world Foxconn. Its workers work 12 hours a day. There is no overtime and no benefits what soever. Workers commit suicide not able to bear with the conditions at factory.( Please see the reports in web). Apple had found its labor practices wanting in many respects. It is the largest company in the world with 62 billion turnover ( which is higher than combined turnover of Apple, MS, HP. It has employee strength of 8,00,000 and likely to touch 10,00,000. Is it possible to compete with him with all our quality prescriptions? The organization also adopt similar practices but with a difference, just no responsibility towards workers.However, its gets its designs from US and manufactures at a price that is unbeatable in the world. However, my suggestion is build products that are suitable to India. Design them in such a fashion that they totally fit to the local needs such as the Delhi sound systems that are sold cheap in Delhi streets. I am preparing case studies on products that are designed with fit to the social and anthropological system of India. Any one to help me? |
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Design the products which are / will become necessary for people in their day to day life. Improving the design according to need of people. The manufacturing plant should be always near to raw material, maintaining the good quality of the product at affordable price, make the workers work efficiently in the quality time provided to them, the rate of production will depend on rate of sale. Use the technology to improve and speed up the production of the product, Advertising. After survey, if the product is doing successful business then thinking to extend the service by availability of the product nearer to the customer layout. One example which made a record, I would like everybody to remember Indian railways, when the train fare is brought down in peak hours, when compared to bus fare. People opted for train service rather than bus service, because more comfortable yet low cost at peak hour. This made no loss for railway and at the same time profit for people made more people to use service and this made profit for Indian railways.
Design the products which are / will become necessary for people in their day to day life. Improving the design according to need of people. The manufacturing plant should be always near to raw material, maintaining the good quality of the product at affordable price, make the workers work efficiently in the quality time provided to them, the rate of production will depend on rate of sale. Use the technology to improve and speed up the production of the product, Advertising. After survey, if the product is doing successful business then thinking to extend the service by availability of the product nearer to the customer layout. One example which made a record, I would like everybody to remember Indian railways, when the train fare is brought down in peak hours, when compared to bus fare. People opted for train service rather than bus service, because more comfortable yet low cost at peak hour. This made no loss for railway and at the same time profit for people made more people to use service and this made profit for Indian railways.
Yes Sir, i can help you in your studies if you want.
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Value engineering & Analysis are the most important tools to study,analyse, operate & cut the un necessary costs. VSM is the technique which focusses on business, product & processes, identifies critical & non critical (non value adding items) so as to cut costs & time required for a process in particular. After all, for businesses all over the world, TIME=MONEY!!!! |
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A manufacturing plant needs good production planning to achieve targets. Therefore it should have a good production planning team, who can give the right direction to achieve the goals. When you produce the material in good quantities and with good quality then we make good profits also. |
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The initial requirement to manufacture anything is core knowledge about the product and then comes the manufacturing techniques which comprises of processes and required fail safe,user friendly equipments and the technical support to manufacture those equipments and dedicated labour force to do the job.Quality should not be checked as it has to be put in. kndevasenapathy@gmail.com
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Programmed Mechatronics devices can produce with highest level of accuracy. From core mechanical (i.e. a lathe machine) to auto ancillary every process, if associated with some intelligent machine can deliver more in terms of production, accuracy and cost effectiveness.
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Manufacturers who design new products
should consider rapid prototyping. This process will allow
manufacturers to inexpensively produce a prototype for their company without investing in super expensive machinery. The benefit to
this is that if a prototype is scrapped before production ever begins,
then the machinery that was purchased to create that prototype would
have to be scrapped as well. However, if rapid prototyping is
implemented, then companies will be able to test a product before
investing high amounts of money, preventing a possible loss.
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Hello, If one has to make manufacturing plant more profitable then fist of all market research/survey is necessary and what our competitor adopt the technology which increase the popularity/demand of their product with competitive rate factor. Because one can increase the profitability of manufacturing plant by adopting latest upcoming technologies with proper strength of team work between two hands so that if hands burn then both hands can burn nobody can alone clap without other hand.
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waste is the prime factor which effect profit,u mst take into account the factors which reduces wastage during production..especially of rejection,rejection can be minimized by making process more friendly n easy,these six sigma,lean method approach is good in respect for higher production n better quality.
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Take the 100% of the capabilities out from the key employee by keeping their moral high, providing the best of the facilities to them, keep them updated with changes and give proper training besides working on details on cost cutting factors efficiently. Market research has to be strong. One counselor should be there in each of your offices to deal with customer as well as with employee. |
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implementing TPM and TQM methadology enhance the staff which was actually our front line managers and all the supposer attahed with them
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co-operation and inter action have no alternative.
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Proper management of: Goods, man power & machinery to get production in right time. To get this we need to have very good tuning between all departments of a plant. |
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I fully agree with you, to have a very good tuning of the departments . What you mean by tuning is reducing unwanted / inactive workmethods /processess /wrong material inputs. and of course correct attitudes and job ownership of all the employees. We have to start from the basics before we talk about LEAN, GREEN or TOYOTA PRODUCTION SYSTEMS. Have we completed systems like 5S , Kizan or Work study Methods ? If so we can try other Tools which are more advanced. I see lots of organisation still in the initial stage but they have to go long way to achieve more profits to the organisation so lets start doing basic to enjoy higher profits.
I fully agree with you, to have a very good tuning of the departments . What you mean by tuning is reducing unwanted / inactive workmethods /processess /wrong material inputs. and of course correct attitudes and job ownership of all the employees. We have to start from the basics before we talk about LEAN, GREEN or TOYOTA PRODUCTION SYSTEMS. Have we completed systems like 5S , Kizan or Work study Methods ? If so we can try other Tools which are more advanced. I see lots of organisation still in the initial stage but they have to go long way to achieve more profits to the organisation so lets start doing basic to enjoy higher profits.
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I think discrete manufacturing organizations must make their own standards & systems of processes & procedures.They can use the available benchmarks for reference.
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GOOD PLANNING.FOR REDUCE BREAK DOWN GOOD QUALITY OF SPARE AND TRAINED WORKER AND STAFF. RECYCLE OF WASTE . ENERGY SAVING . HIGH SPEED MACHINE FOR MORE PRODUCTION. |
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When you manufacture something , there have to be wastage of raw material or some thing like energy/water etc. , A manufacturer has to put a plant to his existing plant which will be called recovery of raw material which is wasted during the manufacturing process and after recovery it can be used for fresh use, hence the loss will be stop. There can be losses due to power cuts so there should be stand by DG set to run in emergency cases, in short the manufacturer should follow all the new technology in his manufacturing process which will meet the international standards as well.
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firt of all u should have the basic knowledge of material science.
using the most suitable and economical material for manufacturing is the key to profitable manufacturing.inventry control and other factors as transportation are also responsible for low profit in manufacturing.
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The answer to this problem lies in seeking solution for the bleeding happening. A profit making unit gradually becomes complacent. The easiest method that most follow is increasing the sales price. If there is a critical analysis of most of the manufacturing unit, it could be found that the cost of production is 15 to 20% higher than what it should be. My experience in the food processing industry, has taught me this and we could turn around an export oriented company from achieving regularly break even figure to 15% profit, with still a lot of scope left behind. The secret is in measuring the variables, distinguishing between "need & necessity", making staff participate and strictly standing by the decision and monitoring the result. It is really fun doing this exercise. If there is anybody who will require my service may contact me: karnalson@yahoo.com or sandoz2009@gmail.com or 09910143571 |
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Lean Projects are very Good for Higher Cost reduction in plant
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If manufacturing plant follows effective process plan then i am sure that it can experience profit in no time. Also, it should share profit with the employee because for any company employees are assets.
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An organization is what it's people makes it. People's involvement aligned with Business Policy makes an organization profitable
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An organization is what it's people makes it. People's involvement aligned with Business Policy makes an organization profitable. Invest in people, they will create profit centres.
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Idea is to provide more options for your product.(but it should involve critical points in mind)not to disrupt its basic use.. Some innovations is required which is the demand of todays market condition. Like a wind cheater--can be used for style,trendy,raincoat and in winter too. |
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Lots of resources are wasted during the process of Manufacturing, be it Energy, rawmaterial or other stores items. KEY WORD is Saving (conservation). Save on every itemand increase profitability. There may not be one thing on which you can save a lot but there are lots of things on which you can save little and make a lot.
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It is essential to have clear process for each activity with time schedule and monitering of the same. Link remuneration to the production for all function with a severe penalty for rejection. Give special incentive for process improvement. Ensure least stores and goods.
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As one our frnd said that the model wise parts will change its desighn.If we centralised the part as per the levels then we can maitain the less types of parts and less desighns will be their then the supply becomes easy to delaer.The parts delay will not happend in delear ships then the customer issues will reduses then ultimately the customer delight improves and the repeted customer purchase happen the profitability of Manufaturer will increases.The delear confussion decreses according to parts.If the mobel wise change dose not happen then manufacturer will supply easily the parts issues will decreses then delear can serve with out delay with that customer happy. In this way we can reduce wastage of non moving raw material for non moving models.And non moving stock we can adjust for fast moving vehicle.The profitability of Manufacturers will rapidly increses. |
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become complete coustomer oriented,read the avenue change startegy with prevailing situations.
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Using proper technology will not only save time, man power, materials but also give the right kind of edge in the market. Cost effective technology added with proper cost control is the right tool to run the manufacturing plant profitably.
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Using proper technology will not only save time, man power, materials but also give the right kind of edge in the market. Cost effective technology added with proper cost control is the right tool to run the manufacturing plant profitably.
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Using proper technology will not only save time, man power, materials but also give the right kind of edge in the market. Cost effective technology added with proper cost control is the right tool to run the manufacturing plant profitably.
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Using proper technology will not only save time, man power, materials but also give the right kind of edge in the market. Cost effective technology added with proper cost control is the right tool to run the manufacturing plant profitably.
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A company can implement six sigma strategies, strategic planning, better strategic management, TQM (top quality management) and outsourcing.Outsourcing can help you to streamline your business, improve on your operations and improve on your profitability. Outsourcing can do a lot to be beneficial to a company that’s big or small. Outsourcing can help you to bring new products to market faster. Outsourcing can help manufacturers meet or beat many business challenges, increase operational efficiency and help a company to step ahead of competitors. You can outsource your non-core business activities. You could use outsourcing for administrative business management support. Many companies use outsourcing to improve productivity, efficiency and profitability. But when in doubt consider business consulting to help make better strategic decisions about business management and operations. ~Business Consulting Services & Outsourcing Services: You can contact CEO Business Management Solutions for business consulting services, strategic planning and business management services: www.CEOBusinessManagement.com |
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witout skilled manpower thre is no profits
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First of all have a look existing business practices. If found any scope of improvement(s) try it with full diligence. Second find out the ways to cut cost from small small areas like power cost, water cost, etc. Used recycled products where ever possible. Because penny and penny makes many.
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Benchmarking in terms of quality in every possible sector makes a manufacturing unit more profitable.
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Still we see that many manufacturing plants are averse or not aware of the benefits that the IT enabled facilities would extend when integrated into their processes. Although there would be computers available within the manufacturing facility, many employees are still not aware of the positive impact on productivity.
Also there are many introduction and training sessions on Lean practices across the manufacturing units but the integration with the processes and running SS projects for benefits remains Adhoc. There seems to be a hesitation from Manufacturing unit heads to sponsor and encourage the initiatives due to lack of confidence in the concept or loss of productive hours on the initiatives.
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Get work done with Planning and Controlling systems
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A manufacturing unit should concentrate on core items & technology. Resource allocation for manufacture of non-critical and common standard items only increases the total cost of manufacture.
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Use the right strategy to make your manufacturing plant more profitable.Like rolling and hiring of labour, right stocking policy, right product mix, targeting market etc.
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Proper Maintenance,Timing-increase factoring timing,Add new to your manufacturing product
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Proper Maintenance,Timing-increase factoring timing,Add new to your manufacturing product....i m new in entrepreneurship let's see how i will proceed in Toostep
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Proper incentive scheme and multitasking may be of help |
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Incentive scheme and musltitasking may be of help. Thank you |
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Kaizen that must be followed by the manufacturing organizations if they want to run profitably. another thing which they can introduce is the quality circle. quality circles will come uup with improvements that are very cheap and easy to implement but will be very fruitful in long run.quality circles will also lead to better co ordination and bonding between workers and hence will lower down the iteration rate and hence improve on the profitability by cutting the cost incurred in hiring and training the new entrants.
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A WORK ENVIRONMENT NEEDS TO BE CREATED WHERE REPRESENTATIVES FROM ZERO LEVEL TO THE HIGHEST LEVEL IN INDUSTRY HIERARCHY SHOULD MEET TOGETHER AN DISCUSS WHAT CAN BE DONE ON THEIR LEVEL AND THERE SHOULD BE EXCHANGE OF IDEAS AMONG THEM SO THAT THE PROBABILITY OF OCCURRENCE OF ERROR IS REDUCED.
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A manufacturing plant should change production procedures and policies according modern technology. Changing times also brings with it cost effective technology, so a plant change and adopt new technology to match need of time and market.
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Gentlemen / ladies I agree with you all, but if you put all these 5 points together and see the results. The basic requirements to make the manufacturing unit profitable is to control the wastage, bring it down to minimum, Everything including the raw material, electricity, water and man power. These are the main factors affect the manufacturing cost, and if controlled properly can give the maximum profit.
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Reduce the cycle time which reduces other lean times which leads to more productivity..
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Ther are plenty of management principles,theories and prctices employed in manufacturing industry and making it profitable at every stage or in every process all around the world.It is not possible to make any one metod a perfect one.The profitability can be increased by doing thorough research in perticular process of manufacturing and sorting out all potential threats to the profit.
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1) Go from bottom to top.The workers have great ideas than the people in A/C rooms.
2)Avoid meetings always, if your planning is well, scope is clear, roles and responsibilities of resources defined ,dont interfere in execution.
3)too many cooks will spoil the food.
4)Engineers always differ. Choose the technology to be adopted by brain storming,script is over, strightly go for cashflow and ROI,
5)facilitate the staff they will work,productivity not by reports it will be seen .
6)Hitlerisam wont work, even hitler was defeated.
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Viewing thing in a wholistic way can be the answer. Insted of isolated quality manageemnt , companies should go with integrated Total Quality Management which may result in risk pooling .Chasing Quality will definately be a better option to opt.
"Chase Quality and quantity will chase you"
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With time, we will comprehensively bankrupt the oil majors, and do no good for anyone else. Is there a way out ? |
The manufacturing process is very complex. It is made up of multiple elements that make many number of problems possible. Let us formulate few suggestions on how to make manufacturing more profitable. Any ideas would be appreciated. Thanks !!! |