| Controlled Manufacturing |
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Margins are tight, repsonsiveness is
everything. Making a product with the minimum of setup and adjustment are part of manufacturing in the developed world.
It is no longer enough to follow the setup, adjust and re-adjust conventional manufacturing mantra. European manufacturers need to be there first and produce efficiently. |
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We did it right once before didn't we?
All of your manufacturing processes will have been producing goods which are in specification. At this point were you aware of the inputs to the process? Probably not and you would not be alone, most companies in the UK do not record process inputs.
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Surely there is a better way...
The first step is to record inputs to a machine or process in order to see what is happening. There may be some quantities that are varying without anyone on the shop floor or in engineering or management teams knowing about it. Is it possible to minimise the variance?
The second step is to inspect the product. You will then see when you are making good product.
The third step is to compare inputs to outputs, that is to say what are the inputs when you are making good product.
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Consider the following case study...
Customer A has a process which has a number of inputs, temperatures, pressures and speeds. The customer also has in the region of about 200 products.
By correlating the data from inspection and SPC with inputs from the process; customer A was able to reduce the time taken from setting up to running good product by an average of 50%. This also facilitated a set of "recipes" by product type.
The customer now knows what to setings the process inputs need to be to create good product . |
This has had the effect of cutting costs by:
Reducing set up scrap.
Reducing planned non productive time.
Reducing non productive labour time.
Reducing engineering and management troubleshooting time.
When UK and European manufacturing have already been under pressure to cut costs, the current recession demands a step change in the way wo do things in the manufacturing sector. The UK government also made reference to developing advanced manufacturing techniques, Controlled Manufacturing is what we at CimWorks UK Ltd are calling it.
Contact us for more information or to arrange a presentation.
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