Managing the Production Floor through the Implementation of Manufacturing Execution Systems

The most productive approach to managing a process is to understand that it is accomplished with two thoughts in mind:

1. Develop an efficient process
2. Design the system to support that process

ASSESS THE MANUFACTURING PROCESS

Managing a manufacturing process continues to be a problem with no one perfect solution. In reality, a system must recognize the type of manufacturing process that is to be managed before it can be efficiently designed and implemented. Start with a thorough analysis of your current process and system and be prepared to change or update it frequently by continually applying Lean Manufacturing Concepts.

Answer these questions.

• Are our constraints specifically identified?
• Are our work-in-process lead times greater than twice the standard manufacturing run times?
• Do we change priorities during the WIP lead-time?
• Do my set-up times force lot sizes?
• Are there quality problems during the manufacturing process?
• Are component items timed to be completed with matching parts?
• Are my costs climbing?
• Are customers dissatisfied?
• Do I have process capability?
• Does the system provide the information to answer the preceding questions?

Design a system to fit the business needs

It must first be recognized that a manufacturing process must support both the business needs and the Supply Chain needs. Companies such as Dell, GE and Intel are successful in their respective fields in part because they designed their manufacturing processes to fit the absolute need to satisfy the marketplace.

These Are The Steps For Our Process Flow Modeling Program

• Define the current process (Process Map)
• Design what the flow could be using our unique Process Flow Model
• Identify all types of waste
• Develop a plan to :
  - Reduce labor and overhead costs
  - Reduce inventory
  - Reduce lead times
  - Increase customer satisfaction dramatically
  
• Incorporate major change
  - 90 Day disciplined teams focused on major breakthroughs
• Evaluate your progress
• Sustain the process

Typically, a Shop Floor Control system is designed or purchased to fit current conditions, without regard to the fact that the process has inherent problems that make it impossible to satisfy business requirements.

Shop floor control system objectives

A Shop Floor Control system must accomplish a variety of tasks, provide many types of information and be capable of changing quickly to changing demands.

Requirements of a shop floor control system

• Provides scheduling which includes priority, short term load, resource grouping and tracking.
• Causes the product to flow through in a "single piece flow" manner.
• Calculates both available capacity and current and future loads on that capacity.
• Capable of increasing or decreasing output to meet current demand.
• Collects actual costs associated with the manufacture of products in a simplistic manner.
• Attains quality objectives
• Meets ERP, Master Scheduling or customer ordered required dates.
• Provides knowledge of material required.
• Accounts for scrap, rework and cost variances.

The need for flexibility

The manufacturing world has learned to be reactive to marketplace needs; therefore incapable processes will inhibit manufacturing firms' ability to compete. The partnership of a manufacturing process and the system that supports it must result in having the flexibility to meet the needs of the customers regardless of the degree of change.

Employment of superior shop floor control practices

• Cellular Manufacturing Principles
• Constraint Management
• Kanban Flow Techniques
• Continuous Improvement Mentality
• Demand Pull Flow Technology
• Product Synchronization Process
• Synchronized With The Supply Chain
• Lean Manufacturing Concepts
• Cycle Time Calculations
• Line balancing (TAKT Time)
• Flexible Capacity Planning Techniques
• Employee Involvement

The Benefits Of A New Process

• Short lead times through flexible processes
• Schedules that truly represent the customers needs
• Waste reduction techniques throughout the process
• Innovative process improvements that will cut labor and overhead by two thirds
• Quality initiatives that will significantly reduce scrap, rework and customer returns
• Customer partnerships with longevity

Contact us to learn more about our multi-step approach to managing the flow of product through your plant and our fast-paced approach in implementing a shop floor control system that will cause your product to flow.

Our three to five day comprehensive assessment will put you on the path of:

• Reduced work-in-process inventory
• Increased market share
• Satisfied customers
• Reduced costs
• Predictable quality levels
• Improved profits

In many industries market share and customer satisfaction will be won or lost based on manufacturing system performance. Don't lose your manufacturing competency to the competitors or suppliers. Build an internal continuous assessment and change program that maximizes profits and perpetuates a core competency.