Even as production managers spend considerable time on these items, every production unit face three major problems:
- Increasing WIP inventory
- Discrepancies in fixed rate of throughput
- Unmanageable rate of rework and rejections
The reason behind the lack of accuracy often includes the inefficient process of production distribution across lines that reduces the rate of throughput thus increasing inventory that is work-in-progress. Without data to understand each worker’s performance level, the rate of rejections also increase over time.
Thus, managers do not have the entire picture of the production floor to create a productive plan for execution due to the following reasons.
- Lack of visibility of actual outputs or cycle time
- Work assigned solely on availability of capacity without target consideration
- Measuring rejections with parameters other than lost time, capacity or output
- Failure to optimise productivity
Planning / Controlling with PlanIT
8 / 10 line managers spend significant time and effort to create a production plan.
However, the current operations that are conducted across many departments work at SILOS focused on individual objectives. Each department sets their own objective for the product line and use a rule of thumb for line planning.
To end this process, did the management ever feel a holistic system could revolutionise the manufacturing unit of the business? A single application with 360-degree view of the floor with the flexibility to monitor all aspects including materials availability, quality check, rejections monitor, workers’ performance. A solution that can transform the operations to become more responsive.