1. How to increase the size of a plant without adding new square feet of floor?
2. How can you reduce your production costs without increasing the workload of your employees?
3. How to diversify your product range without increasing your inventory level?
4. How can employees be encouraged to take charge?
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1. HOW TO INCREASE THE SIZE OF A FACTORY WITHOUT MULTIPLYING THE NUMBER OF SQUARE FEET?
- Our factories are too large even if we lack space.
- So we need to optimize the available floor space.
- We want to enlarge from the inside.
- In order to optimize the available space, we must:
- Reduce the inventory of products in progress by reducing the size of batches to be manufactured;
- Reducing the passage time of the control by optimizing the process in a cellular arrangement;
- Optimize the bottleneck in order to maximize the flow and thus increase the production capacity of the plant;
- Reorganize the plant (5S) to optimize space;
- Control the inventory level of raw materials, finished products and finished products.
All this is therefore aimed at maximizing the space by optimizing the manufacturing process.
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2. HOW TO DECREASE YOUR PRODUCTION COSTS WITHOUT INCREASING EMPLOYEES ‘EMPLOYEES?
We are asking employees to work at their normal pace. Without working faster or stronger, we can increase employee efficiency by improving the system (environment) that surrounds them.
So we have to :
- Reduce non-value added transactions;
- Eliminate waste in the plant;
- Optimize the bottleneck;
- Redefine a new, more efficient process;
- Maximize the% use of machines;
- Rearrange the workstations in order to be as efficient as possible (5S).
Your employees will therefore become more efficient without working harder living in a better, more secure environment.
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3. HOW DO YOU DIVERSIFY YOUR PRODUCT RANGE WITHOUT INCREASING YOUR INVENTORY LEVEL?
To give you a greater variety while optimizing your manufacturing process you must:
- Reduce the setup time of the machines;
- Reduce lot sizes;
- Closer workstations.
By reducing the start-up time by 50%, you can reduce your batches by 50% and thus produce two (2) different products instead of one (1) alone, in the same amount of time used. At the end, your inventories of finished products will be reduced and your product turnover will be faster. You can make your products that sell well more regularly and the others will stay in your warehouses for a shorter period of time.
Despite a higher range of products, you will more easily control inventories and your manufacturing time will be better.
^ Back to top4. HOW CAN THE EMPLOYEES TAKE THE TASTE?
- Traditionally, employees have never been listened to and have been unable to participate in business improvement.
- Ideas (suggestions), progress groups and even re-engineering did not work because we wanted to impose things on the workers.
- The PVA philosophy with the Kaizen methodology promotes the participation (involvement) of employees in the improvement of the company.
- Employees are the experts in what they do, so it is they who are best placed to be part of a multidisciplinary team to improve the business.
Your employees will therefore be very proud to participate in the development of their business.