Data-driven Manufacturing

Data-driven Manufacturing

Overview of The Goal Book

"The Goal" by Eliyahu Goldratt presents the Theory of Constraints (TOC) - a management paradigm that views any manageable system as being limited by a small number of constraints. Goldratt uses an engaging narrative to show how a struggling factory is turned profitable by employing TOC principles. It highlights that amplifying throughput, not cost optimization, must be the focal point of manufacturing. TOC's principles center around "Five Focusing Steps (Identify, Exploit, Subordinate, Elevate, Iterate)", which help address internal and external constraints of a system. The book also expounds on how TOC affects inventory management, arguing for buffer inventory that solely supports throughput. It propagates "Throughput Accounting" focusing on truly variable costs and advocates balancing flow rather than capacity in a manufacturing system. It also explores the concept of batch sizes, set up times, and the role of bottlenecks, emphasizing effective management of the latter. Overall, "The Goal" breaks down complex managerial concepts into easily understandable nuggets using real-world examples and continually stresses on incremental improvements for optimal productivity.

Dive deeper into these fascinating efficiency-oriented principles by reading "The Goal" in full.

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How to Measure Rework ($ Labor & Materials)

Rework in manufacturing refers to the repeat of tasks due to errors or defects, which can be costly in terms of time and resources. Measuring rework, therefore, not only helps identify waste but offers valuable insights into areas for improvement. This can impact product quality, process efficiencies, and overall profitability. Rework involves labor, i.e., human resources engaged in correcting these errors, and rework materials, encompassing all the raw materials, components, or elements used in the correction process. There are various strategies for measuring these aspects, such as time tracking or average hours method for labor and quantitative analysis of material volume for materials. The use of technology, proactive identification of potential reworks, materials management and procurement strategies can help reduce rework rates. By effectively implementing and continually evaluating these strategies, manufacturers can optimize production. For more in-depth understanding, read the full article.

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Developing KPIs for Manufacturing Team Performance

Key Performance Indicators (KPIs) are vital tools for enhancing manufacturing processes, acting as benchmarks for driving productivity, quality, and efficiency. Notable KPIs include Overall Equipment Effectiveness (OEE) and First Pass Yield (FPY), both of which measure production efficiency and output quality. However, to fully exploit these KPIs, Production Managers must clearly define these measures and ensure they align with team activities and company objectives. The process of setting KPIs should follow the SMART criterion, meaning they should be specific, measurable, attainable, relevant and time-bound. Implementing a robust tracking system, such as a Manufacturing Execution System (MES), aids in real-time tracking of these KPIs. Regular review of KPIs, good communication and feedback within the team are all crucial for continual growth and performance improvement. Equip yourself with deeper understanding of KPIs and their proper implementation by diving into the full article.

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