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By : Isha Verma, Sales/BD Manager, Larsen & Toubro
Activity:  16 comments  5497 views  last activity : 07 06 2010 20:18:04 +0000
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                        10 ways to improve manufacturing productivity

I think manufacturing performance and production analysis improves productivity with full production machine data collection systems.

Maximizing productivity is a never-ending task for most freelancers. There’s always some way that we can improve or some area that’s lacking the attention it deserves. This post serves as a guide and a reminder for ways that we can get more done and make better use of our time.Here I have discussed 10 ways to improve manufacturing productivity

1) Analyze causes for downtime and rejects: Record and analyze machine downtime and reject events to minimize interruptions and poor productivity.

2) Monitor machines in real time:Detect problems before productivity and quality suffers: see real-time displays of efficiency, utilization, OEE, yield, rate, cycle time.

3) Automate production reporting:Implement automated production data collection and reporting from ALL types of production machines. Print standard and custom reports automatically and export data to Excel, 1-2-3 or your Enterprise systems.

4) Automate production scheduling, job tracking:Reduce time-consuming manual production scheduling and job tracking chores to just a few clicks of a mouse.

5)  Schedule P.M. based on actual machine/tool use:Don't wait for your machinery to break or produce scrap before you perform maintenance. Instead, be proactive: schedule Preventive Maintenance based on actual machine/tool/component usage: run hours and cycle count.

6) Analyze manufacturing process variable performance:Monitor temperature, pressure, cushion, shot size, stroke, shut height, tonnage, inject/fill/hold time, etc. Chart as X bar and R or export it to SQC/SPC applications.

7) Implement OEE/ISO/Continuous Improvement programs:Develop real-world production standards to make your job costing accurate. Implement activity based costing, Continuous Improvement and OEE programs.

8) Manufacturing data collection for ERP, MES, CMMS systems:

Close the loop with your Enterprise systems: Automatically download production schedules into System's Job Queue, then upload production/performance/productivity and usage data at Shift and Job end.

9) Export cycle counts and run time to CMMS systems. Eliminate manual "meter" reading and data collection: ProductionACE can export actual runtime and cycle counts to any third-party CMMS/EAM software during the production shift: cycle counts and runtime "meters" are updated in a real-time file.

10) Read and Print Bar Code labels at each machine as parts are made: Printed labels can contain your choice of information such as Product Description, Work Order #, Operator Name, Date/Time, Lot Number, etc.
    


 Top Comment : Vinit Gupta   | 04 24 2009 10:44:38 +0000
Really great points for improving manufacturing productivity.But I want to add one more point to it. Productivity solutions - for predicting performance and results in turning In todays machine shops, productivity factors usually go hand in hand and many look towards achieving as much as possible in respect to all of them. Continual lowering of production costs is a priority for maintaining competitiveness whatever the type of manufacturing by making sure the machine shop has access to the best tools and services, one is making sure of maximising the manufacturing potential through: 1. Output and quality being maximised, 2. Turning performance and security being optimized, 3. Tools selected and applied being fewer and better and 4. Tool inventory and handling being minimised.
 
16 comments on "10 ways to improve manufacturing productivity"
  Commented by  Arunraj, Engineer - New Product Development, Koyas Fasteners Pvt Ltd    | 07 12 2009 09:35:26 +0000
Rating : +1 
Nice article Isha and point added by Shyam & Hardik are also worth. My suggestion is POKA YOKE to be introduced in the process to avoid the regections, which will improve the productivity.
  Commented by  sujit, PGP Student, Batch of 2010, IIM Kozhikode    | 06 12 2009 10:19:19 +0000
Rating : +1 
What a writing Isha ji, exactly, thanks for sharing. Nic article indeed.
  Commented by  K. R. Prasanna Venkatesan, Associate/Senior Associate, SIIPL    | 05 12 2009 05:49:52 +0000
Rating : +1 
Dear All
Nice article and useful comments... 
In my view, implementation of any technique will be complete only when there is a mutual involvement of the implementer as well as the end user of the implemented process.
If the end user is interested in the technique that we implement (May be a small improvement or a total change in system), the implementation will be a full sucess.
Even there is any bottleneck in the implementation the end user will give suggestion in improveing the implementation part and making it a practical implementation.
So the first thing an implementer shoul do is clear the initial resistance to change creating awareness on the benefits and by proper training.
  Commented by  jairaj shyam prasad, Production Manager, BOSCH Ltd    | 05 07 2009 13:27:48 +0000
Rating : +1 
nice article Isha.yes point are valid enough to enhance productivity,but implementation part? in my own experience,even though we have all these points are in place and monitored daily,still i feel it is the man who works actually in the process will have a final say for any positive result.management will certainly implement all these things at least in the view of any system audits but will it give any results instantly is a question.i just want to add that we have introduced ANDON syatems for key processes and linked to OEE to know the real capacity losses/time which may be useful.lastly, unless there is a flexible workforce in any industry,these things will not have any early returns.
  Commented by  Isha Verma, Sales/BD Manager, Larsen & Toubro    | 05 07 2009 09:53:13 +0000
Rating : +1 
yes shyam your points are valid. Definitely its worth to consider lean but ultimately it's a one piece flow which have its own bottlenecks...

Thanks for adding your own list.
  Commented by  Shyam Dikshit, Partner/Principal/VP, VAWE Solutions    | 05 06 2009 14:34:23 +0000
Rating : +3 
I disagree with the points mentioned. Monitoring does not improve productivity but actions generated from such data gives you guideline where to act. Also extend and method of implementation depends on Business. Lean provides excellent systematic productivity improvement and it creates culture which is much better than just few actions. Sustenance of productivity through Lean is better than those suggested as they are evolved by user team. 
What points have been mentioned may be true for particular production line how ever does not have state-of-art flavour. Use of Lean tools provides productivity improvement for all the industries and businesses. Adding value and elimination of waste will improve productivity. To my opinion followings should be considered for Productivity Improvement.
1.	Have multi-skilled production team to meet fluctuating customer demand and tackling absenteeism.
2.	Have small batches preferably single piece flow and takt time production. Reduce distances.
3.	Standardize processes. Implement 5S. Introduce PDCA for continuous Improvement.
4.	Use quality tools. Quality issue – Prevent defect going to customer first by segregation (Correction), then quickly modify process so that defect does not arise (Corrective action), deploy solution at all places where applicable (Preventive action).  Prefer quality by process over quality by human skills.
5.	Introduce measurements for productivity measurements. Cycle Time, first pass yield, Overall Equipment availability rate etc. Initiate actions when variations are observed to fix issues.
6.	Have Total Productive Maintenance to improve cycle time and equipment availability rate. Use of Poke-Yoke, external setup, single  minute exchange of die etc..
7.	Have visual signals, POKE YOKE, Kaizen etc.
These can be adopted by any one at low cost.
Regards
  Commented by  Hardik Bhavsar, Service/Maintenance Engineer Tiffany Foods Ltd    | 05 06 2009 14:05:44 +0000
Rating : +1 
Very nice and to the point article. Predictive maintenance is also to be added in this.
  Commented by  Isha Verma, Sales/BD Manager, Larsen & Toubro    | 05 06 2009 10:46:36 +0000
Thanks all of you guys for your wonderful comments.....
  Commented by  Akash, International Marketing Shabro    | 05 06 2009 09:50:04 +0000
Rating : +1 
Nice article. I would like to add another point:
Implement productivity enhancements methods like value engineering, TQM. In India Indian Soceity of Value Engineering (INVEST) helps to implement Value Engineering practices.
  Commented by  AMOD KUMAR YADAV, Manager - Projects Sales & Marketing, RDK INTERNATIONAL LIGHTING LLC    | 05 05 2009 10:38:55 +0000
Rating : +1 
So refreshing article Isha.Venkatesan and Samir have added some good points. Thanks for sharing.
  Commented by  venkatesan, Marketing Manager, eskay cartons pvt ltd    | 04 30 2009 14:40:26 +0000
Rating : +1 
apart from those valid points, we need to take up preventive maintanance as a culture instead of attending to breakdowns at the last moment.
  Commented by  Tata V.S. Kameswara Rao, Consultant - Srtategic Automotive Sales & Customer Care    | 04 26 2009 06:02:16 +0000
Excellent excercise. Good to share
  Commented by  Sanjit Biswas, Sales/BD Manager, Larsen & Toubro    | 04 24 2009 11:21:42 +0000
Rating : +1 
Well Isha I would like to say it will work up to some extent.But good sharing.
  Commented by  Sameer Joshi, Project Manager, ADP    | 04 24 2009 11:10:35 +0000
Rating : +1 
Nice article .Well, I wanna to add some more point to manufacturing productivity:-

1)Maintaining production security with predictable tool-life 
2)Quality consistency - without continuous supervision and adjustments
3)Minimising tool inventory - and having the right tool when needed 

What do you say guys?
  Commented by  Puneet Maurya, Project Lead, Aftek    | 04 24 2009 10:59:54 +0000
 

Really some nice points there Isha....great post..thanks for sharing.

  Commented by  Vinit Gupta, Sales/BD Manager, Larsen & Toubro    | 04 24 2009 10:44:38 +0000
Rating : +2 
Really great points for improving manufacturing productivity.But I want to add one more point to it.
Productivity solutions - for predicting performance and results in turning
In todays machine shops, productivity factors usually go hand in hand and many look towards achieving as much as possible in respect to all of them. Continual lowering of production costs is a priority for maintaining competitiveness whatever the type of manufacturing by making sure the machine shop has access to the best tools and services, one is making sure of maximising the manufacturing potential through:
1. Output and quality being maximised,
2. Turning performance and security being optimized,
3. Tools selected and applied being fewer and better and
4. Tool inventory and handling being minimised. 
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