Project of the Month


"Production planning = Accountability"


Improving accountability and productivity through production planning, defined production requirements, clear target specifications for machine use, and actual deviation monitoring.

RESULTS

Increase in output

by ~ 40%

Increase in efficiency

by ~ 30%

EXISTING SITUATION

  • No consistent, mandatory production planning and control - constant short-term changes and adjustments
  • Non optimal use of machines and systems - OEE data collection and daily monitoring is missing as part of the production meetings.
  • Planning requirements and work orders do not live up to expectations.
  • The product range to be produced is too extensive. - As a result, there is a high set-up rate.
  • Machines and systems can only be used to a limited extent due to a lack of qualified personnel.
  • Lack of prioritization of key systems (bottlenecks), provision of personnel and compliance with training.
  • Frequent machine and plant malfunctions, which are hardly or not effectively processed.
  • Cascading communication process is not adhered to. – Procedure is unclear.

APPROACH

  • Understand the current situation and determine the causes, e.g. documentation, missing processes, missing KPIs, production planning and control process
  • Define production-relevant requirements and set up necessary planning data i.e. system capacities, personnel, shifts and throughput times.
  • Define personnel structure / personnel requirements assessment and necessary adjustments - create flexibility.
  • Employee training – increasing the level of knowledge, creating understanding in order to better understand connections and dependencies.
  • Coaching of production-, area- and shift management and corresponding shop floor management introduced.
  • Improved communication and problem solving between the direct and indirect production-related departments
  • Set-up optimization and 5S workshops implemented consistently and goal-oriented
  • Downtime - OEE monitoring - importance - improved
  • Production planning and control process defined, necessary throughput times determined - "Frozen" zone for stabilization and process compliance enforced