What do you do if your manufacturing operations are inefficient and outdated?

Begin by constructing an event-based production model that integrates people, processes, and technology flow. Identify any gaps in this model. Once you have developed the production model, it will facilitate the creation of a roadmap and value plan. I will be discussing this topic at Automate 2024.

If your manufacturing operations are inefficient AND outdated, I recommend getting fresh eyes to review the process. Outdated, to me, implies that the inefficiencies have been tolerated by those conducting and leading the operations. So, they might not be able to SEE opportunities. 1) Install visual management of the processes. Identify inefficiencies, stoppages, issues...anything that was activity that WASN'T producing parts. 2) Start daily accountability meetings to track the effort to address the issues captured in the visual management tools. 3) Implement Leader Standard Work to monitor and sustain standard work, visual management, accountability, and continuous improvement. Shoot me a DM if you want to discuss these tools.

In order to come out of the crisis, you need to assess the current state, find out how all the undesirable effects are connected with each other to find the root cause. This helps in taking action on few critical areas and results in big and quick gains. Focus on what is hindering flow and systematically improve it. This may require training and other related policies to change for motivating the employees. Do not try to cut costs and sack people, you will land up cutting muscles more than fat and lose production capacity and available knowledge.

Evaluate organization and roles and responsibilities to understand strengths weaknesses and inefficiencies... Value stream mapping along with FMEA to understand loss. Cycle time study for equipment capacity for improvement. Analyze profit loss for potential growth and budget for understanding money side for improvement.

Once the gaps are identified, consider upgrading outdated machinery and equipment with newer, more efficient models. This can lead to increased production capacity, improved quality control, and reduced waste.

One thing which could help is to invest in training programs to equip our employees with the skills necessary to operate new technologies and implement improved processes.

Depending on your specific needs, outsourcing certain aspects of your manufacturing operations could be a viable solution. This can free up resources and allow you to focus on your core competencies. Also consulting with manufacturing specialists can provide valuable guidance and assistance in implementing new improvements.

in unrecorded down time, one of the hidden problem is poor communication and delay between production and maintenance teams. I cut short this item and I recruted new technical operators and I promoted the good operators who has knowllede in maintenance. And Idjust their salaries accordingly. Breakdown has been minimized . Gaps in communications been closed.

If the system is very very old and revamping is expensive.... No use of discussing all these points. All needed to align old with new to a certain extent. So that capital cost can control up to a certain extent so that..can get longer time to replace....along with productions.. keep continuing...so we can at least got opex from production...till system renewed.