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There are two main causes for production bottlenecks:

  1. Poor line balancing – some jobs are running slower than others, and materials pile up in front of the slowest ones.
  2. Poor process control and/or poor maintenance – the equipment does not run as it was designed to run. It is often down or busy re-processing materials.

In this post I'll focus on the first cause...

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Topics: Avoiding bottlenecks, Process Improvement

A few weeks ago I read an article titled; 'Is there a formula to predict or evaluate the success of a lean implementation?' written by Art Byrne. He has led Lean transformations in the US for 30 years at very senior levels, so he has a few ideas about what process improvement goals are realistic. Read on to explore this further...

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Topics: Management/Turnaround, Process Improvement

Tired of improvement initiatives that get everybody excited, but die after 2 months? 
Frustrated by changes that don't "stick" in the long term? 

CMC's manufacturing consultants have formulated a tried-and-tested process improvement framework that we use when working with clients to improve their manufacturing operations.

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Topics: Management/Turnaround, Process Improvement

In the course of our work, we see organizations that tackle ambitious projects, select some lean process improvement tools, and fail miserably.
CMC published an example that combines several of these mistakes in this article about problem solving. I think we see such an example 3-5 times a week, sadly.

Here are 4 common mistakes one needs to watch out for... 

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Topics: Lean Manufacturing, Management/Turnaround, Process Improvement

Many readers shared an article we published two weeks ago, Setting Up A Step-By-Step Process Improvement Plan In Your Factory, and we got some great feedback. By popular demand, we decided to dive deeper into this topic.

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Topics: Management/Turnaround, Process Improvement

Do you want a process improvement plan for your factory, in order to improve quality, reduce cost, and deliver on time? And are you wondering, ‘is there a step-by-step approach?'

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Topics: Quality, Process Improvement

Do you complain about your Chinese suppliers’ inconsistent quality? Are you wondering why they can’t keep making good products?

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Topics: Quality, Process control systems, Process Improvement

So management is committed to improving your factory’s operations, but they are not sure what to focus on? Are they focused on the right process improvement goals?

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Topics: Management/Turnaround, Process Improvement

In an earlier article we emphasized the importance of production planning for PCB manufacturing. Another critical success factor is controlling components before PCB assembly (incoming quality control) and segregating bad components.

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Topics: Process Improvement

Manufacturing of printed circuit boards (PCB) with an automated surface mount assembly (SMA) line consists of the following sequence of operations:

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Topics: Process Improvement

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