Struggling to improve manufacturing operations efficiency?

Se você está lutando para melhorar a eficiência das opera??es, comece reduzindo sua poupan?a, reduza seus estoques, os problemas v?o come?ar a aparecer rapidamente e precisam ser resolvidos com a mesma rapidez. No centro destas mudan?as est?o as pessoas que s?o responsáveis pelas solu??es dos problemas. Quando este processo vira uma rotina, iniciamos uma jornada na dire??o de desenvolvermos uma organiza??o sustentável baseado na melhoria continua.

Start with the people to embrace common Lean mind set. Simple explain: No more, no less, just what is necessary! This rule stays for all: Planning, Logistic, Warehouse, Preparation process, Production. Make your processes transparent- can be under control in every moment. Keep Production floor visible from all points- you can make visible all types of waste. Design& mark area for materials, semi-finished goods, rework, scrap, final control, that you can fit in them "no more, no less, just what is necessary". Make Value stream mapping and reorganize your production lines to have the shortest flow from start to the end (one piece flow if possible). Organize your line feeding with "no more, no less, just what is necessary" for every 1-2 hours.

For example: you have a product, as a set of 3 parts with different lead times working in one line. Pace of the line is 20 sets/hour. Write this on the line Info table. Analyze the timings for each part separately and organize production line so each part will be as close as possible to the line pace. Stop overproduction of the part which has the smallest time when reach 20pcs/ hour and redirect the operators to production of the part with highest time until reach 20pcs/ hour and then turn them back on production of the first part. Your line will be in balance. For this you need high skilled people,trained for more machines, operations and products.

Technology is powerful if it is implemented properly and used effectively. On the reverse of this, getting this wrong can have ramifications for the business in terms of cost and time, but also in the relationship with the operators themselves.

. A motivated and empowered workforce is instrumental in maximizing the return on capital investments and automation. By fostering a culture of continuous improvement, involving employees in decision-making, and recognizing their contributions, organizations can unlock their full operational potential. Without employee buy-in, even the most advanced technologies and processes will fall short of their expected outcomes.

In my experience,there are a few things giving good results. It is necessary to start train people for multiple machines/operations/ products on the very beginning. Keep them rotate on different positions on, lat's say, weekly bases, so you can maintain their skills over time. Utilize unique information system, to avoid double data reproduction in administration/reporting process and free more time for your people for creative actions: Auto control, Issue detection, Problem solving, Suggestions for improvement. Utilize integrated individual rewarding system for contributions regarding individual efficiency, quality and their engagement. The system provides also the data about individual skill matrix, rotation frequency and training plan.