Plant Processes

Increase the capacity and quality of plant operations while reducing lead-time and cost via the transformation of the manufacturing process that increases value.

The demands on today’s manufacturing professionals are high. Global competition and compliance requirements are challenging at best. The issues facing many business leaders are that of overall efficiency. How does one get the most out of employee resources, without exploitation? Keeping the production team safe and happy are key. Although increasing capacity, with less rework, while reducing lead-time and cost seems counter-intuitive, that’s exactly the prescription for success. Especially, when considering that a positive effect on quality is also expected. Under today’s business conditions, head counts are frozen; at best. Compounding the issue is that many departments are sharing resources. These people are already working "hard"; however, they need to work "smart".

The answer is to transform the existing manufacturing processes while leveraging the resources currently in place. The full value of the existing team can be realized through the development and implementation of robust, manufacturing processes that focus on throughput. Six Sigma methodologies are widely proven to improve manufacturing operations by establishing effective workflow, capability, and quality; without the proportional increase in resources. What is not widely recognized is that these optimizations can be realized collectively. Through proper process design, work is able to flow, optimally timed, from one station to another. Additional capacity is realized, lead-time is reduced, costs are minimized, and rework is virtually eliminated. However, one unexpected benefit is that overall product quality is improved as team members are generally more satisfied by the work being accomplished in a more comfortable environment; see examples below.

TransR Plant Processes

Through this deployment of LEAN, Design For Six Sigma (DFSS), and other methodologies, the shop floor can be transformed to leverage its resources to deliver more products, in shorter time, with less overall cost; while improving quality. What was a fragmented collection of players, is now a high performing team that delivers world-class value - "attaining the capacity, throughput, lead-time, cost, and quality improvements; simultaneously".

See All Foundation Solutions

Foundation Solutions are focused upon Business Process Transformation of key processes throughout the enterprise, and Secure Collaboration supporting your enterprise's interaction with suppliers, partners and customers. For all the processes below, a PLM system should be evaluated as a potential framework to institutionalize those processes.

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