How do you create efficient production systems for manufacturing?

1/2 systematically addressing and clearly outline your production goals and objectives and understand what you aim to achieve in terms of production volume, quality, and cost and design a streamlined and logical workflow to minimize unnecessary movements and wastage Standardize production processes to ensure consistency and create work instructions, procedures, and operating parameters. and adopt principles from lean manufacturing and production system from any good company like Suzuki, Siemens, Honda etc implement advanced technologies such as LCA automation, robotics ,IOT and industry4.0 systems with data analytics to improve efficiency and focus on training and people involvement:

In addition to the above points, sometimes customer satisfaction is not just a number. Small things like a detailed installation manual, some extra hardware along with the dispatched FG, online availability of your post sales service team etc matter a lot. Specially when you are in a project based manufacturing company.

As per my experience in FMCG manufacturing, making an efficient production system means optimizing processes for smooth, cost-effective, and high-quality manufacturing. Accurate demand forecasting is key, use historical data and market trends, plan ROQ based Just-In-Time production to cut waste, automation for efficiency. Maximize equipment use, collaborate with suppliers, and manage quality at every stage of the production to minimize defects for customer satisfaction. Use ERP to track and manage inventory levels. Train and engage staff for efficiency and implement KPIs based reviews on production related metrics to review process and resources. Stay compliant, use data analytics for insights, and benchmark against industry best practices.

2/2 Ensure that your workforce is well-trained and involved in the improvement process. Encourage a culture of continuous improvement and empower employees to suggest and implement changes and ensure effective and reliable SCM. also focus of quality assurance over quality control and motivate people for Kaizen culture and utilize KPIs and adopt flexibility and adaptability

Consider your metrics and their definition very carefully. Ensure they reflect the performance you value. Remember, what gets measured determine behaviour!

When choosing a production layout, consider factors like production volume and product variety. For high-volume, standardized production, a product layout (line flow) minimizes material handling by arranging workstations sequentially. In contrast, a process layout (functional flow) groups workstations by function, suitable for low-volume, custom production. Cellular layout (cell flow) combines elements of both, organizing self-contained cells for specific products or processes, promoting efficiency and flexibility. A hybrid layout may integrate features from multiple layouts. Evaluate each option based on productivity optimization, workflow support, and alignment with business goals.

A layout should probably be one of the last things you actually put in place. Figure out what you're building, how you're building it, and how it best makes sense to break it up. Basically everything else. Then you can worry about laying it out in the most efficient way for all the other stuff you've tackled first.

using lagging indicators to identify areas for improvement, applying the 80/20 principle to prioritize efforts, and implementing lean concepts to make targeted improvements efficiently

It is important to start with the simplest and most objective process possible to meet your needs. It has to be as continuous as possible and with a minimum of intermediate stock.

On top of Lean Principle, I would even more recommend applying the principle in Factory Physics as it explain the "WHY" of why certain program work/didn't work in a specific timeframe. With a strong understanding of those principle, ones is able to maneuver the team through high and low of the production cycle.

When implementing lean manufacturing principles it is critical to remember that your first customer is the team of people executing the process. Your goal may be to reduce defects, improve output, or eliminate costs, but those only happen with buy-in from the team. Having an established culture of collaboration and a foundation of continuous improvement will help drive effective solutions. Excellent culture, good data, and strong lean principles will lead you to sustained results.

Right tools right time The tool box is large but use appropriately I’ve seen companies bogged down in forms and wasteful activities supposedly implemented as part of lean strategy, keep it real Team buy in is key at all levels or won’t work Understand processes by mapping, look for improvements and remove bottlenecks Use Gemba to monitor and manage real time

Great idea, If really implemented. Can save time and money, and that makes everyone happy from manufacturing companies to customers.

Implementation of lean tools is the best way to create efficient manufacturing system. Lean tools automatically create the system of manufacturing processes.

Insights about the data is perhaps even more critical than plotting the data itself. With clear insights, decision can be made at the front line, this empowering the team and boost the performance tremendously.

Automation is one of manufacturing’s greatest allies in the search for the best results. Mainly in simple and repetitive activities and in the integration of processes. Digitization also plays an important role in the agility of making information available, as well as in collecting and processing it for continuous improvement actions.

One thing I've found really helpful is benchmarking of the processes and then working on them regularly to improve. Line rebalancing on regular basis, and with clear target expectations will drive improvements across many functions, including quality, process and definitely costs. It will also keep teams engaged and always looking out for 8 wastes reduction. Eventually team would drive those events without much need of influencing from the leadership teams, as long as there is recognition. It is always a domino effect and it can go either way.

It is very important to have the key process indicators well defined. Thus, with a reliable data collection and processing system, we can use the most basic tool, PDCA, to make the process of continuous improvement happen and then support the results of the operation.

I am a big fan of RCA, it is a powerful tool for finding and fixing the root causes of problems in your production system. By understanding the root cause of a problem, you can implement a lasting solution that will improve your system and prevent reoccurrences. As a firm believer in continuous improvement, I find root cause analysis is a great way to look for opportunities to learn from mistakes and forge better and more efficient systems.

Monitor processes and look for trends, share and challenge concerns Data is key, to make considered decisions you need to understand what is really going on at ground zero

Yes, continuously monitoring is very effective way to make systems efficient. When you monitor the same then you analyse & improve your barriers.

1.An efficient production system need to be viewed always from 4M point of view. 2.'Zero defect' must be aimed always with the philosophy of -I will not accept defects -I will not make defects -I will not pass defects -I will rotate PDCA cycle always. 3.TPM is key for uninterrupted production and high OEE. 4.'Digital twin' will give a lot of insight for carrying out predictive maitenance to give zero interruption. 5.Continuous training of people is another point to be kept in mind.

In my experience In the production set up, I would like to add that Encouraging a culture of continuous improvement where employees actively seek ways to optimize their work would help create an efficient production system for manufacturing. Apart from this, developing a contingency plan to help address potential disruptions in the production process.

Production system which works on PULL System and manufacture products as per the Pull of customer demands of required Quantity with Best Qaulity and maintain less inventories from raw materials to finished goods in the entire supply chain cycle . 1.JIT and JIS 2.Zero Rejections / Less Rejections 3.Best built in Quality Products. 4.Produces what is required , when required , How much required with min WIP . 5.Meets customer expectations on time. 6.Flow like a waterfall as per customer demands in the entire Process of Manufacturing. 7.Order to Delivery lead time is as minimum possible follow Pull system of Production in OEM and Suppliers

Bring in dedicated people, working as team, empowered to make sure goals are achieved, that is system. Industry 4.0 is taking over manufacturing, not to mention robotics operations which is already at its full scale, all we need now is to have the right attitude and dedication to make things happen in our operations.

Another LI article full of useless jargon and not much in the way of content...sigh And it needs a minimum number of characters to note that..........