Daily production management is a continuous performance improvement process. It ensures that the work is carried out according to the best standards to achieve high operational efficiency (OEE). Each event during production will be analyzed for root causes and may lead to a change of standards.
We focus on performance relevant KPI and capability building in your existing team right at the production line to ensure sustainable implementation. Operator and middle management are enabled to follow daily routines and Standard Working Processes (SWP) based on autonomous- and preventive maintenance and refined in numerous implementations.
The daily production management solution considers the individual maturity level and provides an interconnected road map that guides operations through work packages to achieve process excellence.
Our KPI calculation might differ from site to site.
How do disruptive technologies such as IoT or Smart Factory fit in my current process, and what is the return of technology?
Although we invest quite some effort in Operational Excellence the OEE stuck at around 45%.
Decisions are taken based on experience, not on data.
Workforce teams are not sharing knowledge and not connected to central improvements.
Common challenges we see in daily production management.
Increase transparency and confidence in decision making
Decrease number of stops by 30%
Reduce Scrap up to 60%
Increase of efficiency by up to 15% within 12 weeks
Increase motivation on leadership and operator level through ownership
Up to 70% increase in mean time between failure
Typical annualized savings over US$1MM per plant
Sustainable results through high performing and self directive teams in your organization.
We initiate actionable measures with a short- to long-term impact. Our approach is based on three phases: gaining transparency, discovery, and implementation. Our standardized Prove of Value (POV) is designed for 2-3 pilot lines and takes 14 weeks. The rollout can be executed by client organizations, leveraging the capabilities of our AIO platform.
We apply a site survey to identify relevant data and processes and the organizational maturity level in the transparency phase. We also set-up user group-oriented dashboards to get daily information on online performance and process compliance.
Within the discovery phase, we define targets and thresholds for each KPI to allow AI/ML-based detection of an abnormal pattern, and alerts emphasize abnormalities and encourage to take action.
In the implementation phase, you learn to take advantage of the data by improving the standards. All activities are guided by daily loss analysis to ensure reliable processes and showcase performance improvements right at your production line, in particular unplanned downtime.
This management consulting approach is based on our AIO platform.