Utilization Charts Equipment
View equipment use efficiency and downtime to optimize operational performance.
Identifying manufacturing process improvements with discrete capacity modeling and bottleneck analysis.
Creating capacity and throughput models identify which resources or machines are bottlenecks in your processes. These models are used to determine if additional equipment, docks, operators or operating shifts are required to produce a desired throughput. They are used to identify the bottlenecks of your current resources; determine how much more throughput each resource can handle before adding more equipment or shifts and help cost justify new investments by calculating additional income from additional throughput.
Creating capacity models has you ask the right questions that identify leading downtime and bottleneck causes. Return-On-Investment (ROI) calculations can then be performed on whether reducing downtimes, automating or investing capital into new equipment is the right solution.
Performing a manufacturing bottleneck analysis teaches you where you can improve your productivity. Productivity Solutions has developed several Excel based tracking sheets that easily logs and reports the quantity and duration of downtime or scrap causes in your processes.
Capacity Modeling and Bottleneck Analysis Applications:
- Manufacturing Process Design – Identifies how much equipment is required to produce a specified throughput using a defined staffing plan.
- Calculating Required Staffing – Identifies how many operators are required.
- Document current set-up times and downtime causes for process improvement opportunities.
- Verify that scheduling plans and feasible.
- Assist with level loading equipment.
- Comprehensive labor analysis that establishes production targets or labor reduction goals.
Key benefits include:
- Identifying process improvements to eliminate or minimize bottlenecks.
- Increased productivity.
- Reduced labor costs.
- Providing quantitative data for equipment ROI justifications.
- Calculating how much equipment is required for a desired throughput.
Borden Chemicals & Plastics – Operational Efficiency Analysis for Labor & Machinery
PVC and acrylic powder processing plant.
- Performed a staffing reduction project that identified non-capital proposals, capital projects and combined proposals.
- Performed assessment, training and documentation of current tasks, resource loading with Ghant Charts.
- Evaluated the operational cost impact of several different staffing calculations and recommendations with management.
Fiberglass Panel Manufacturer for the Recreational Vehicle Industry – Labor Equipment Utilization Analysis
As a premier Fiberglass Panel Manufacturer catering to the Recreational Vehicle Industry, we’ve undertaken a comprehensive analysis of Equipment Utilization to streamline our manufacturing processes. Our method involves spraying chopped glass and polymers onto molds, followed by cutting and packaging these large panels efficiently.
A detailed labor analysis we conducted led to a significant 25% boost in production efficiency. This improvement is a testament to our commitment to optimizing operations and delivering quality products more swiftly.
Sprays chopped glass and polymers on molds, cuts and packages large panels.
- Performed a labor analysis the resulted in a 25% increase in production efficiency.
- Provided data collection procedures, production target tables and operator utilization calculations for analyzing and identifying process improvements.