I will try and sound like an expert....
Industrial Food manufacturing involves a great deal of effort, discipline, infrastructure, technology and team work. The need to manufacture food productively is the requirement these days to survive in any business. All manufacturing units require a production facility, where the goods are produced. The production process comprises of man, machines and material. Proper allocation of jobs, resources, production floor layout and material results in cost efficient production.
To remain competitive, most companies use various methodologies such as Lean Manufacturing to reduce waste, Six Sigma to increase quality, TPM to improve reliability and many team engagement programs for uplifting performance, in order to improve manufacturing productivity. By implementing these programs, companies bring products to market more quickly, ensure customer satisfaction and maintain their market share. Improving manufacturing productivity involves collecting and analyzing data and making effective decisions. Ensuring the success of these operational excellence initiatives often depends on divisions working together to share data and interpret it appropriately.
Identify the work flow associated with manufacturing your product. This includes the people, processes and technology required for production as well as the resources, communication and procedures needed throughout the company. Value stream mapping helps business professionals assess, monitor and identify process improvement projects and then help them prioritize the action plan.
Track reports to analyze financial and customer satisfaction data. Share the same comprehensive data with all stake holders, so that they can develop manufacturing process improvement plans, assign resources to complete the tasks, manage the budgets and determine if the projects met their goals.
Create a balanced report based on actual performance metrics and data. Identify financial measures for the report such as monthly sales, customer measures such as the number of product support calls, process measures such as number of products manufactured each month and employee measures such as staff retention. As you implement process improvement changes, note any changes in these operational measures to validate that your interventions were successful.
Monitor information generated from process improvement projects to implement improvements throughout all of your manufacturing operations. Analyze costs and benefits. Share reports and all the relevant information. Ensure all employees have access to the information and appropriate training on how to implement the procedures to improve manufacturing productivity.
The essence of improving manufacturing productivity can be summed up very simply as:-
• Accurately capture information that identifies your losses (Information)
• Use that information to identify your priorities (Focus)
• Take thoughtful, thorough, and sustained action (Action)
TPM (Total Productive Maintenance), OEE (Overall Equipment Effectiveness is one of the most important elements of Lean Manufacturing. OEE measures the percentage of Planned Production Time that is truly productive. An OEE score of 100% represents ideal and perfect Production: manufacturing only good parts, as fast as possible (at rated capacity), with no down time.
OEE is calculated from three underlying factors: Availability, Performance, and Quality. Each of these factors represents a different perspective for how close your manufacturing process is to ideal and perfect Production.
Essentially, productivity can be improved by best possible utilization of resources and devising and implementing the systems and procedures which help in producing safe products with minimal costs. To achieve this, companies can work on
Standardize work procedures. The handling of product and raw material should be reduced to minimum by either putting of conveyors or automatic transfer to the machine. Automation is the key. Adequate focus should be given to employee engagement, involvement and productivity and all if the below
• WORK STANDARDS
• MANPOWER ALLOCATION PER MACHINE
• WORK AND TIME STUDY
• PHYSICAL STRESS
• Reduce changeover time for machines
• Autonomous maintenance of Machine
• Implement required mix of preventive and predictive Maintenance
In a productive workplace, employees are more concerned with getting results rather than talking about results. Communication is important for a productive workplace, but doing the job is what gets the results. Create performance metrics that employees need to achieve, and make the achievement of those metrics part of the employee performance review. Avoid drawn-out conversations about getting the job done, and insist on getting to work instead.
More than anything else, work in the right direction and try and do your best and help others to perform at their best!