Factory floor issues you may be experiencing

Labour intensive manual processes
  • We manually collect production data.
  • We have no accurate information on how much scrap we actually make.
  • Our reporting is quite often out of date by the time we finish collecting the data.
  • Our historic information is stored on paper production sheets.
  • It takes us ages to investigate and analyse our problems.
  • The OEE figure we report is not accurate.

This can’t go on!

 

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Inaccurate planning and scheduling
  • Our wall planner is past its use by date.
  • It’s very hard to change the plan on the spreadsheet.
  • When our planner is away, we struggle as it’s so complicated.
  • The start and finish times of jobs are not very accurate.
  • We have no smart way of planning tool changes, colour changes or preparing jobs.
  • Customer orders are quite often late due to a whole raft of reasons.

This can’t go on!

 

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Poor visibility
  • We know how many products are made on each shift but are not sure if the production is consistent and to standard throughout the entire process.
  • We are never quite sure what downtimes we had on the afternoon and night shifts.
  • We have no easy way of identifying problems as they happen.
  • We are always fire-fighting.
  • When a machine is down we quite often don’t know for a while.
  • We have no good way of communicating information between shifts.

This can’t go on!

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Tribal knowledge
  • Our job run data is kept in manual folders which are hard to keep up to date.
  • It would be good to know how we compare to World’s Best Practice. I suspect we would be a long way off the mark.
  • We know how long it should take to do a tool change but we’re not sure actually how long it does take.
  • We have no way of standardising our performance or measuring OEE in order to be consistent each time we make a part.
  • Our Tool Setter likes to make his own machine settings.
  • We have no consistent standardised QA process across all jobs.

This can’t go on!

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We’ve always done it like this!
  • We don’t use any modern technology on the shop-floor.
  • We are old fashioned in the way we work.
  • We don’t have very good control or visibility of the factory floor.
  • We lack a good quality production process.
  • We lack integrated front-office and production systems.
  • Our Owner/GM doesn’t believe in shop-floor automation.

This can’t go on!

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