It is also crucial to follow their production very closely. Delays should never be discovered at the last minute!
At the same time, mistake-proofing each process can prevent or catch human errors before they become mistakes. And procedures to look for the root cause immediately when new issues arise will reduce the occurrence of defects over time.
Time-tested preventive / predictive maintenance can help increase the OEE (Overall Equipment Effectiveness) ratio dramatically.
Because they have no realistic production planning system to work with.
A simple Excel spreadsheet can often do the job. And, as the organization becomes more mature, a kanban system can gradually be put in place.
Our Suzhou factory was unable to ramp up production to fulfill our sales. This caused a lot of missed deadlines on critical shipments, not to mention lost sales. CMC consultants used LEAN tools and immediately identified bottlenecks. They quickly elevated the factory's production capacity, and then worked on stabilizing processes and increasing efficiencies. They have done a great job, and we are now working with them on our 2nd and 3rd most critical factories in China.
Our management team was not displaying the energy my partners and I expected of them. By working with them on a few meaningful metrics for each department, and teaching us how to hold "daily accountability meetings" CMC created noticeable change in our factory. Now our managers spend hours each day on improvement projects, rather than their daily routine operations.
Our planning process started showing its limits when volume increased suddenly last year. We were not sure what to do. Did we need a more powerful ERP? Did we need a totally different approach? We were lucky to find CMC, who sent us a planning & purchasing specialist and immediately made very relevant recommendations. After one month the planning process and the communication among departments was already a lot smoother.
Factory General Manager