There is no shortage of advice about what it takes to become a world-class leader in any field. For manufacturing companies this leads to any number of production methodologies, technology choices, and systems you can use to reduce resource requirements and increase productivity.
Deciding what will work for you, or even what your first step should look like can be a daunting task.
Having worked with a lot of world-class companies in almost any industry you can imagine, we have seen what works and what doesn't work time and time again. Our job is to give our customers a tried and true method of making their lives easier, and we ask a lot of questions when given the opportunity. A result of all of our research is this list of 25 things world-class companies have used to become leaders in their field and maintain their lead through the years.
Please take a look at the list and see if it matches up with your needs, and if we missed something, or you want any more information on our experience with any items, please let us know.
Here is the list, in no particular order:
- Process-change management tracking system, with approvals/notifications
- Implement real-time cost per-unit system
- Automated waste/energy management tracking system
- Implement a product lifecycle management (PLM) system
- Plant-wide operator team goals (production, safety, optimization)
- Web-based system to replace hand-written operator logs
- Production demand/forecast modeling
- Process heat recycling
- Implement a behavior based safety program
- Document process best practices, make them available in HMI application
- Implement process troubleshooting workflows to address common issues, alarms, etc.
- Cause and effect diagrams for each process step to address product quality and waste issues
- Standardize operating ranges, setpoints, and targets for process conditions on a per-product basis
- Centralized asset management system
- Implement process historian
- Manufacturing Execution/Manufacturing Operation Management System implementation
- Install real-time process dashboards/KPI displays throughout the plant
- Upgrade HMI/operator interface screens to High-Performance HMI standards
- Improve flow of information from QA/QC to operators prior to packaging
- Statistical Process Control (SPC) implementation
- Overall Equipment Effectiveness (OEE) tracking
- Company-wide innovation stimulation program, support new ideas from staff, outside sources, etc.
- Computerized Maintenance Management Systems (CMMS), predictive maintenance program
- Implement an emission monitoring/reduction program
- Process-wide Value Stream Mapping system