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Managing complex product variants is a difficult task. One that is often made more difficult by outdated paper-based product data. Our latest case study explores how Lifetime Products overcame product variant challenges and achieved better collaboration, change management, and product quality by switching from paper-based to digital bill of materials (BOMs) https://lnkd.in/dqvYXxDj

Managing complex product variants is a difficult task. One that is often made more difficult by outdated paper-based product data. Our latest case study explores how Lifetime Products overcame product variant challenges and achieved better collaboration, change management, and product quality by switching from paper-based to digital bill of materials (BOMs) https://lnkd.in/gWrxW-ZE

Managing complex product variants is a difficult task. One that is often made more difficult by outdated paper-based product data. Our latest case study explores how Lifetime Products overcame product variant challenges and achieved better collaboration, change management, and product quality by switching from paper-based to digital bill of materials (BOMs) https://lnkd.in/gACwKNMP

I’ve just finished the course “How to create mixed model value streams” through the Institute for Operational Excellence. Created by Kevin Duggan, these principles help us gain control in complex environments where we have a high variety of products (including made-to-order) with fluctuating demand, that flow through shared production resources. I’ve worked with a lot of companies in this situation. The high variety of products means lots of changeovers, so the go-to solution is to increase batch sizes. The fluctuating demand may result in a lot of out-of-stocks, so the go-to solution is to increase finished goods inventory. Erratic demand may lead to incomplete parts orders from suppliers, so we create longer queue-before times. Expediting is often needed to keep some customers happy, so we’re constantly changing our production schedule. Duggan’s approach is the opposite and it’s classic Lean thinking. Reduce batch sizes. Reduce inventory. Reduce lead times. Make processes stable and predictable. Make work flow and let the customer pull. It’s how he does it that I've found really interesting. ·     By creating product families, we can group like process steps together and plan them as a family. This immediately reduces complexity. ·     By identifying the pacemaker process, we can calculate the takt time at the pacemaker that sets the rhythm for the whole value stream. ·     Understanding every product and every interval (EPEI) helps us work toward smaller batch sizes. In turn smaller batch sizes reduce lead times. ·     Balancing flow helps us optimise our capacity. But first we need to understand the work that needs to be performed at each workstation. Operator balance charts help us do this. ·     Setting the pitch frequency for withdrawing finished goods from the pacemaker helps us deliver to customer demand. Duggan uses the simple analogy of a train timetable. The pitch is like the train travelling to the timetable. It arrives at the set time to withdraw the finished goods from the pacemaker. If the goods aren’t ready on time, the train must stop, and we immediately know there's an interruption to flow. ·     Creating a production schedule that shows real-time performance. The schedule reflects the pitch increments at each process and is the guiding plan for achieving flow. For those of you working in settings with a mix of products flowing through shared resources, I highly recommend this course and the book.

"If only we had ______" fill in the blank: a) thought of that earlier, b) invested more upfront, c) made more detailed plans, d) asked that before we started, e) others? I don't know if prolific author Dennis Brewer used that phrase in any of his books, but I remember when he said it to me: I was racing out the door for maybe a pick-up ball game in the schoolyard, and he called me back inside to redo a chore that I had hastily deemed finished. When I whined that I didn't have time, he told me when you don't have time, you'd better take your time to do it right the first time, so you're not wasting your time redoing it. I have seen that played out so many times in manufacturing, as the fill in the blank above may make you think of a time or two (or more), when you encountered a problem that could have been avoided had someone spent a little more time upfront. Focusing on first-time quality is a great example. Unfortunately, it often takes measuring the cost of bad quality to make the business case to fix the process to avoid the mistakes. Ironically, the process could have been fixed before it ever went wrong for a lot less cost. I'm referring to taking seriously the steps in Advanced Product Quality Planning (APQP) rather than the often rubber-stamp/cut-and-paste approach, or worse, the excuse that it costs too much in upfront engineering and operations time. Instead, organizations would rather spend a lot more in bad quality, late deliveries, irate customers, expedited freight, on top of the engineering and operations time to fix it later, when a real data-point tabulation of costs can be put to it. Instead, follow the age-old wisdom to take your time to ask all of the questions, put together the detailed plans, think of things that could go wrong before they happen, and put plans in place to mitigate the risks and address contingencies. #strategywithactions #planning #APQP #risks #manufacturing #processimprovement #quality #lean #leanmanufacturing

Unlocking Business Success: The Power of Strategic Product Costing 🚀…   In the dynamic landscape of business, staying competitive is not just a goal but a necessity. One key aspect that often gets overlooked is the strategic implementation of product costing. Let's explore how adopting a robust product costing strategy can be a game-changer for your business. 💼 #CostEngineering #Engineering #Costing #ReduceCosts #Manufacturing #ProductCosting #Benefits #Herstellkostensenken #Produktkostenkalkulation #Fertigungskosten #Kostenoptimierung

Ready to streamline your budget and boost your bottom line? Let's talk about your product costing needs! Contact me for expert assistance and personalized solutions. Don't let inefficiencies weigh down your profits and take the first step towards cost-effective success!

In a dynamic business environment, it is essential to adapt . The adoption of Value-Based Pricing emerges as a transformative strategy that not only drives profitability but puts the customer at the center of everything. 🚀 As an advocate of innovation, I can't help but admire how leading companies are defying convention this value-centric approach. It's about deeply understanding customer needs. 👥💡 The flexibility of Value-Based Pricing allows for greater customization, ensuring that customers pay for the true value they receive. It's more than a pricing strategy; it's a cultural shift that drives innovation and improves the customer experience. 🌐💰 As someone committed to sustainable growth, I see this change as an exciting opportunity to align business interests with customer expectations. I'm eager to explore more on this topic and learn from the experiences of other professionals. Is anyone else immersed in the world of Value-Based Pricing? Share your perspectives! 🤝🔍 If you want more information I recommend the article by Utpal M. Dholakia Link:

"* 📝 The Turnaround: Simplifying Complexity with Lean Thinking 💡🔧 "Exploring the concept of simplicity in manufacturing processes and its impact on efficiency and cost-effectiveness." 💭 Lean Thinking Integration: Combining the principles of simplicity with lean thinking for enhanced productivity and reduced complexity. 🔄 Product Turner Automation: Low-cost automation solution for placing products in required orientations during production runs, emphasizing efficiency. 🌐 Harvesting Gravity's Power: Leveraging the force of gravity in manufacturing processes for cost-effective solutions. 📘 KISS Principle: Exploring the "Keep It Simple" principle and its challenges in an increasingly complex environment. 🏗️ Complex vs. Simple: Discussing the paradox of complexity being easy while simplicity poses challenges, highlighting the importance of simplification efforts. 🔄 Continual Improvement: Emphasizing the need for ongoing refinement and optimization in manufacturing processes to adapt to changing demands and technologies. 🌟 Track the Trend: Stay ahead of the curve and explore the possibilities, follow me on Linkedin.com/in/psmahesh ⛷❄🏂🌄 "Credits: 🌟 All write is done by me(P.S.Mahesh) after indepth research. All rights and credits for the video/visual presented are reserved for their respective owners. 📚 For attribution or content removal requests, please contact me. 📩 Only used for Academic Learning/Sharing good work purpose, giving due credit to respective owner 📚 Thank you, and God bless. 🙏"

Reducing lead time in manufacturing is an art. It's the secret sauce that can make your production process more efficient, cost-effective, and competitive. Here's how you can master it 👇 1) Streamline your supply chain.  2) Adopt lean manufacturing principles. 3) Use predictive analytics for demand forecasting. 4) Invest in automation and robotics. 5) Regularly maintain and upgrade your machinery. 6) Cross-train your staff for flexibility. 7) Implement real-time tracking and monitoring. 8) Establish strong relationships with suppliers. 9) Keep a safety stock but don't overstock. 10) Review and optimize your processes regularly. 11) Use a robust ERP system for better coordination. 12) Prioritize quality to reduce rework and defects. 13) Encourage open communication and feedback. 14) Foster a culture of continuous improvement. 15) Don't forget, time is money. This is not an exhaustive list, but it's a good starting point to help you navigate the complex world of manufacturing lead time reduction. Remember, every minute saved in your production process is a minute earned in delivering value to your customers. So, ready to take the lead in reducing lead time? 🚀 Remember, Rome wasn't built in a day. Start small, think big, and never stop improving.