Taking the ideas of the Toyota System and boosting them with today's information systems technology has been the secret to enable some manufacturers to unlock the door that causes a short-cut in procedure improvement jobs. They are rethinking the good ideas of lean manufacturing and are using today's factory flooring details tools to rapidly and quickly enhance factory floor performance, customer responsiveness and their bottom line.
Process enhancement through a leaner technique and finite scheduling for the factory floor can be shown in a variety of ways:
Minimize cycle time
Meet consumer expectations in quality and deliveryLook for methods to improve changeover
Empower the workers
Create a culture for continuous improvement
Producing a "culture" for constant enhancement can be realized through another lean principle' making use of visual help.
By making the factory flooring activity noticeable through the use of the Production Execution System (MES), and determining the flow times of parts on a continuous basis, the factory has a standard from which to recognize areas that need improvement and the system to show those enhancements. For instance, of the factories that are relocating to lean manufacturing, how many have put a machine monitoring devices in location to measure the circulation time of a part? If there is a system that allows this standard metric, the number of can inform the portion of time that parts are being "value-added" verses the waste (or non value-added) time? Time is wasted throughout a downtime event, waiting for a tool/die/mold or other required tool. Other examples of waste are times invested waiting for a quality check or unnecessary time in changeover/set-up. With information systems for factory flooring data collection, the analysis of the factory flooring procedures and the circulation of parts, in some cases described as a "current state map", can be made noticeable. If your company is going do something about it to enhance the procedure then why not make the procedure circulation visible and available all the time, everyday. If enhancement is truly constant, then why make the examination of the flow episodic.So why not think artistically from the get-go and put a factory floor information system in location that can assist you and your company move on with Lean concepts of determining issues, the flow of parts, and step change in time? Just because Toyota did not use electronic information systems, does not make it incorrect to install them on the flooring. To the contrary, it is the American Manufacturer that has the opportunity to improve on these Lean principles with info systems that can be wed into a Lean procedure enhancement program.
- Ensure the entire factory flooring is included with the system which they are empowered to identify problem/alert scenarios.
- Permit the system to supply a JIT production approach, which is dynamic and can be reactive to consumer and floor demands.
- Find a way to record changeover times tracked to particular assets and individuals.
- Identify the opportunities for process improvement and keep a record of it.
- Enable the flooring personnel access to much better communications like email where suitable.
- Enhance the operator's access to data by supplying electronic "paperless" display of current, along with, more recent design electronic image and video documents.
- Make the quality checks part of the procedure and capture it electronically so alert conditions of non-conformance conditions can be recorded in real-time. Execution of
Lean Production through a factory floor system can conserve time and money and put you in the driver seat towards more rewarding production. Think artistically. Use ISO 9001 consultants details tools creatively. Use the details tools that are developed to improve the procedure.
Because 1984, this countryy has actually been a leader in the development, implementation, and support of software products for producing companies. MDSS sells items that help producers better handle stock, shrink cycle time, and boost performance. Their existing focus is a Production Execution System (MES) with modules for time and presence, shop floor management, device monitoring, and more.