What are the Causes of Production Losses in Manufacturing

Sharing the knowledge of what had been learnt from my professional expertise about "What are the real Causes of Production Losses in Manufacturing?"

Production losses can impact small and large companies which usually result from unexpected problems that arise during what should be a routine manufacturing process. Time is added to the process, or the number of items produced falls short of goals, because of issues tied to machinery malfunctions, supply shortages, human error, weather and other issues that companies have varying abilities to control. However, measures can be taken to minimize losses, along with their financial impact through proper planning.

Down-Time Problems:

An industry recognized for manufacturing pointed that equipment efficiency notes that costly down-times issues can be caused by machinery breakdowns, material shortages & issues tied to set ups with necessary adjustments of equipments during production process. Production gets halted due to equipment that fails because it was not properly maintained or repaired and getting it restarted might require calling in maintenance or giving the equipment needed time to warm up.

Speed issues:

The speed of processing can be hampered by brief, sometimes frequent and stops that throw off the general flow of production. These includes insufficient feeds, component invariants and mishaps that occur when, for instance an item falls out or otherwise becomes positioned so that it is blocking a key sensor or delivery point. It had been noted that these stops typically last under five minutes and do not require maintenance but can add up in terms of lost production time.

Production Rejects:

Due to the malfunction of an equipment or processing error, large amounts of product can turn out below accepted standards and needs to be rejected. This can happen when machinery hasn’t been properly set up or warmed up before processing gets underway. Setbacks can also occur due to human error in assembling components which can be done by hand. The rejects may need to be discarded or scrapped, tracking when rejects occur, for instance during a certain work shift or production run; can help to identify patterns that are causing the problems which curb similar incidents in the future.

Prevention Measures:

Tracking maintenance schedules, machinery set up times and other production elements can avert problems. Workable standards date back to the days of Henry Ford’s first auto assembly lines in the early 20th century later honed by Japanese automakers. Toyota Motor Corporation much-emulated "LEAN" manufacturing process aims to completely eliminate waste. When a problem arises, equipment stops immediately, preventing defective products from being produced. Toyota also deploys the concept of "JUST IN-TIME" (J I T) concept in which each process stage produces only what is needed by the next stage in a continuous flow.

SUNDARAMURTHY VELMURUGAN – linkedin.com/in/sundaramurthy velmurugan 299586110 LEATHER PROFESSIONAL CONSULTANT from a2z Leather Professional Consultancy, PONDICHERRY.[email protected] & [email protected] - Whatsapp: +918973231705