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Last updated on 2024年11月14日

How can you identify underperforming areas in your plant?

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If you are in charge of a plant, you know how important it is to monitor and optimize its performance and efficiency. However, sometimes it can be hard to identify which areas of your plant are underperforming and why. In this article, we will share some tips and methods to help you spot and address the weak points in your plant operations.

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CHEIKH SIDATY KEITA

RESPONSABLE MAINTENANCE Unité CSD(Carbonated Soft Drink) lignes canettes et PET chez GROUPE KIRENE

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Tiberiu Bako

AsPET Intermed Bucharest
Marcelo Faria

Engenheiro Industrial | Engenheiro de Processos | Engenheiro de Projetos | Engenheiro Projetista de Ferramentas |…

1 Define your performance indicators

The first step to identify underperforming areas in your plant is to define and measure your key performance indicators (KPIs). KPIs are metrics that reflect how well your plant is achieving its goals and objectives. They can vary depending on the type, size, and industry of your plant, but some common examples are production rate, quality, yield, availability, reliability, and safety. You should choose KPIs that are relevant, measurable, achievable, realistic, and timely, and track them regularly using data collection and analysis tools.

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CHEIKH SIDATY KEITA

RESPONSABLE MAINTENANCE Unité CSD(Carbonated Soft Drink) lignes canettes et PET chez GROUPE KIRENE
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Pour identifier les zones sous-performantes, il est crucial de définir des indicateurs clés de performance (KPI) précis et pertinents, comme les taux de rendement, de défauts et de productivité. Ces KPIs permettent de quantifier les écarts par rapport aux objectifs. Une analyse régulière de ces données révèle les secteurs à améliorer, guidant ainsi les actions correctives et optimisant les performances globales de l’usine.

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Marcelo Faria

Engenheiro Industrial | Engenheiro de Processos | Engenheiro de Projetos | Engenheiro Projetista de Ferramentas | Engenheiro Mecanico | Engenheiro de Produ??o | Engenheiro de Manufatura
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An effective approach to consider is the implementation of OEE (Overall Equipment Effectiveness) among the indicators, as it measures the availability/utilization of equipment, its performance, and the quality of its output. This method is particularly valuable because it connects multiple areas, including Maintenance, Supply Chain, and Quality & Engineering, fostering collaboration and process optimization.

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Eduardo Luiz dos Reis

Gerente de Projetos | Consultor Industrial | Especialista em Ferramentaria, Inje??o Plástica e Alumínio | Fundi??o | Estamparia | Linhas de Montagem
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Para identificar áreas de baixo desempenho, comece definindo indicadores de desempenho (KPIs) que reflitam as metas produtivas e permitam uma análise precisa. Avalie regularmente esses indicadores e compare-os com as metas para identificar desvios. Em seguida, realize uma análise de causa raiz usando ferramentas como o diagrama de Ishikawa ou os 5 Porquês, facilitando a compreens?o dos problemas e a implementa??o de a??es corretivas. Após aplicar as melhorias, monitore o desempenho para confirmar os resultados. Esse ciclo de defini??o, avalia??o, corre??o e monitoramento contínuo é essencial para alcan?ar e sustentar a excelência operacional.

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2 Benchmark your performance

The next step to identify underperforming areas in your plant is to benchmark your performance against your own standards and industry best practices. Benchmarking is the process of comparing your plant's performance with a reference point, such as your past performance, your target performance, or your competitors' performance. This can help you identify gaps, strengths, and weaknesses in your plant operations, and set realistic and attainable improvement goals. You can use benchmarking tools, such as dashboards, scorecards, or reports, to visualize and communicate your performance data.

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CHEIKH SIDATY KEITA

RESPONSABLE MAINTENANCE Unité CSD(Carbonated Soft Drink) lignes canettes et PET chez GROUPE KIRENE
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L’analyse comparative est essentielle pour évaluer la compétitivité et l'efficacité de votre usine. En comparant vos KPIs à des normes internes et aux benchmarks de l'industrie, vous identifiez objectivement les écarts de performance. Des outils comme les tableaux de bord permettent de visualiser ces données, mettant en évidence les points à renforcer pour fixer des objectifs de progrès concrets et atteignables.

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3 Conduct a root cause analysis

The third step to identify underperforming areas in your plant is to conduct a root cause analysis (RCA) to find out why they are underperforming. RCA is a systematic method of identifying and solving problems by tracing them back to their origin. It can help you prevent recurring issues, reduce waste, improve quality, and increase efficiency in your plant operations. You can use RCA tools, such as the 5 Whys, fishbone diagrams, or Pareto charts, to organize and analyze your data and identify the main causes of your underperformance.

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Marcelo Faria

Engenheiro Industrial | Engenheiro de Processos | Engenheiro de Projetos | Engenheiro Projetista de Ferramentas | Engenheiro Mecanico | Engenheiro de Produ??o | Engenheiro de Manufatura
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An interesting approach would be to analyze elements of a process as if viewed in slow motion, mainly those that are often perceived as simple, routine, and unquestionable. Take, for example, the act of drilling a hole. When the button is pressed, electrical energy is activated, causing the mandrel to receive radial acceleration and transfer this motion to the fixed drill bit. By breaking down these steps, we may uncover hidden phenomena that could be the root cause of a specific issue or insight we are seeking.

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CHEIKH SIDATY KEITA

RESPONSABLE MAINTENANCE Unité CSD(Carbonated Soft Drink) lignes canettes et PET chez GROUPE KIRENE
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L'analyse des causes profondes (RCA) est cruciale pour traiter les sous-performances de manière durable. En remontant à l'origine des problèmes, elle permet de prévenir leur récurrence. Les outils comme les 5 pourquoi, les diagrammes en arête de poisson et de Pareto facilitent l'identification des causes racines, optimisant ainsi qualité et efficacité.

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4 Implement corrective actions

The fourth step to identify underperforming areas in your plant is to implement corrective actions to address the root causes of your underperformance. Corrective actions are actions that aim to eliminate or reduce the negative effects of a problem and prevent it from happening again. They can involve changes in processes, equipment, materials, or personnel, depending on the nature and severity of the problem. You should prioritize and plan your corrective actions based on their impact, feasibility, and cost-effectiveness, and monitor their results using feedback loops.

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CHEIKH SIDATY KEITA

RESPONSABLE MAINTENANCE Unité CSD(Carbonated Soft Drink) lignes canettes et PET chez GROUPE KIRENE
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La mise en ?uvre de mesures correctives est essentielle pour éliminer les causes des sous-performances et éviter leur récurrence. Prioriser les actions selon leur impact, faisabilité et co?t garantit une optimisation efficace. Le suivi par boucles de rétroaction permet d’évaluer les améliorations et d’ajuster les actions pour un rendement optimal.

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5 Evaluate and improve your performance

The final step to identify underperforming areas in your plant is to evaluate and improve your performance continuously. Evaluation is the process of assessing the effectiveness and efficiency of your corrective actions and their impact on your performance indicators. Improvement is the process of making further adjustments and enhancements to your corrective actions and your performance indicators based on the evaluation results. You should use evaluation and improvement tools, such as audits, surveys, or PDCA cycles, to ensure that your plant operations are always aligned with your goals and objectives.

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CHEIKH SIDATY KEITA

RESPONSABLE MAINTENANCE Unité CSD(Carbonated Soft Drink) lignes canettes et PET chez GROUPE KIRENE
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L’évaluation continue et l’amélioration sont fondamentales pour maintenir la performance de l’usine. En mesurant l'efficacité des actions correctives, on ajuste les processus en fonction des résultats obtenus. Des outils comme les audits, les enquêtes et les cycles PDCA garantissent un alignement constant des opérations sur les objectifs.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Tiberiu Bako

AsPET Intermed Bucharest
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Look deeply in your P&L, balance sheet and cash flow. The signals are there. Prices ok? Scrap ok? Debts ok? Some important things can be covered in " other costs". Working capital ok? Inventory crystal clear? Slow moving stocks ok? Fraud control ok?

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Gholamreza Golshani

Electrical Engineer ?? | Content Manager?? | Creative Content Creator ? | Content Marketing ?? | I help people promote their efficiency at work.??
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In my view, to identify underperforming areas in your plant, you can consider implementing key performance indicators (KPIs) such as production output, efficiency metrics, downtime analysis, and quality control measures. Regularly monitoring these indicators can help pinpoint areas that may need improvement. Additionally, seeking feedback from employees involved in different processes and conducting thorough inspections can provide valuable insights into potential issues.

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How can you identify underperforming areas in your plant?

1

2

3

4

5

6

1 Define your performance indicators

2 Benchmark your performance

3 Conduct a root cause analysis

4 Implement corrective actions

5 Evaluate and improve your performance

6 Here’s what else to consider

Plant Operations

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How can you identify underperforming areas in your plant?

1

2

3

4

5

6

1 Define your performance indicators

2 Benchmark your performance

3 Conduct a root cause analysis

4 Implement corrective actions

5 Evaluate and improve your performance

6 Here’s what else to consider

Plant Operations

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