More Capacity Without
More Machines
Manufacturing VP shows you how.
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