Ed Ballina, Former Pepsi executive with 30 year manufacturing experience in bottling and paper,
shared his hard won secrets to improving manufacturing capacity without increasing costs;
and how machine health can make those ideas even more powerful.
Ed’s five secrets:
1.Fewer, Shorter Shutdowns
How?
- Reduce maintenance shutdown length and/or frequency
- Defer capital and process projects requiring downtime
- Monitor critical equipment closely to minimize risk from
reduced planned maintenance
How Machine Health Helps
- Prioritizes maintenance tasks to critical equipment that show signs of risk
- Eliminates unnecessary PM windows by consolidating tasks and moving to condition based maintenance
- Real time machine health status allows more reaction time to address issues
2.Use Mothballed Equipment
How?
- Restart decommissioned equipment or lines
- Understand production capabilities of older lines
How Machine Health Helps
- Historical data shows which equipment will require the least effort to recommission, and which components to watch carefully
- Baselining status validates startup of recommissioned equipment
- Continuous monitoring tells you if effort to maintain
outweighs value of restarting
3.Limit SKUs
How?
- Limit production to highest output, margin or most in-demand SKUs
- Be aware of SKU profitability not just production efficiency smaller runs may be more profitable
How Machine Health Helps
- Shows which SKUs have the highest productive output
- Shows which lines are more efficient/reliable at producing
certain SKU’s
4.Stretch Labor Resources
How?
- Reduce staff per line, e.g. enable operators to run multiple
machines - Focus all support personnel on line output, automate other tasks
- Watch line productivity and scrap carefully when teams are stretched
How Machine Health Helps
- Highlights machine trouble spots that need more attention
- Continuous, automated monitoring of equipment gives early warning, minimizes operator time
- Detailed alerts identify likely causes to shorten time/effort to repair
5.Create a Virtual Shift
How?
- Create a virtual shift of off-site staff, vendors and external experts which supports onsite teams
- Identify best experts around the globe from all facilities, create ways for them to collaborate
How Machine Health Helps
- Enables onsite and offsite team to collaborate remotely
- Provides greater clarity into issues to shorten resolution times for internal/external experts
- Validates repairs done by onsite teams
- Provides historical record per machine to get new people up to speed quickly
Interested in Diving Deeper?
Check out Ed’s Webinar on 5 Ways to Increase Capacity in a Crisis