Production Workflow Enhancement

This Foreign Material Failure Saved Us—Here’s How We Turned It Into Quality and Operational Win! Sometimes it takes a near miss to spark real improvement. In this case, it was debris, small splinters from pails that had been stored on in storage racks underneath broken pallets. The failure was caught internally before it became a food safety event, but not before we lost a full batch and had to shut down for hours to clean, inspect, and reset the system. What happened? A temporary “relief” employee stepped in to help during a lunch break. While the primary operator had been trained, the fill-in had not. They dumped the pails into the hopper as instructed, without noticing the debris stuck to the tops. The result? Contamination, downtime, and wasted product. But instead of just moving on, we used the event as a catalyst. We brought the entire team together, including temporary employees, and walked the process from start to finish. What we found were several weak points that, once addressed, not only reduced risk but completely reshaped our operation for the better. Here’s what we changed: - Staged all pails for inspection before entering the batching area, removing debris and damaged containers, while looking at root causes for upstream damage. - Transferred pails to plastic pallets and rinsed them with sanitizing hoses to eliminate dirt, splinters, and potential pathogens. - Verified ingredient accuracy and recorded all lot numbers before transferring them forward. - Installed a macro screen at the hopper and an inline screen, which captured clumps and other materials that previously caused clogs and cleaning delays, speeding up the process and reducing downtime. It also eliminated build up in our PHEs (Plate Heat Exchangers), minimizing the opportunity for biomass. - Expanded this improved workflow to include all bagged and bulk ingredients, mitigating foreign material risks across the board and improving overall process control. - Improved cross-training and awareness, ensuring every person, especially temporary and relief employees, understood food safety and quality expectations tied to their roles. One small failure turned into a major leap forward. It not only improved food safety and team engagement but also minimized the constant start-stop issues in our processing and filling operations. With a steady, clean flow of product to the line, we saw smoother runs and measurably better operational yields. Even more, it led us to identify the root cause of the broken and splintered pallets. a key source of foreign materials. By addressing that, we eliminated a contamination risk and corrected an ongoing issue that was driving pallet loss variances, ultimately recovering unnecessary spend. Efficiency, safety, and cost control gained from one internal catch. If handled properly, failures can turn into great successes!   This photo was AI generated.

𝗬𝗼𝘂𝗿 𝗳𝗮𝗰𝘁𝗼𝗿𝘆 𝗳𝗹𝗼𝗼𝗿 𝗶𝘀 𝘁𝗮𝗹𝗸𝗶𝗻𝗴. 𝗔𝗿𝗲 𝘆𝗼𝘂 𝗹𝗶𝘀𝘁𝗲𝗻𝗶𝗻𝗴? I learned this the hard way. Years ago, I walked the production floor, frustrated by missed deadlines, rework, and the constant firefighting. Operators were searching for misplaced tools, production bottlenecks weren’t clear, and errors weren’t caught early enough. The root cause? Lack of visual management. The moment we implemented clear, intentional visual systems, everything changed. 𝗖𝗼𝗻𝗰𝗲𝗿𝗻: Without visual management, manufacturing floors become chaotic. → Lost tools and materials slow down production. → Quality issues go unnoticed until it’s too late. → Workers waste time searching instead of producing. → Communication breakdowns cause confusion and delays. When critical information isn’t instantly visible, efficiency suffers. 𝗖𝗮𝘂𝘀𝗲: Why do so many manufacturing teams struggle with this? → Leaders assume people "just know" where things are. → Processes rely on memory instead of systems. → Communication is reactive, not proactive. → Workspaces are cluttered with no clear order. Without clear visual cues, productivity is left to chance. 𝗖𝗼𝘂𝗻𝘁𝗲𝗿𝗺𝗲𝗮𝘀𝘂𝗿𝗲: Here’s how to use Visual Management to improve efficiency and reduce errors: → Color-Coded Workspaces: Assign specific colors for tools, zones, and materials for instant recognition. → Shadow Boards & Labels: Every tool has a home - if it’s missing, it’s obvious. → Visual Work Instructions: Use images and diagrams to standardize tasks and reduce training time. → Andon Signals: Real-time alerts for quality issues before defects multiply. → Production Dashboards: Live performance tracking so teams can adjust on the spot. When everything is visible, problems are solved before they escalate. 𝗕𝗲𝗻𝗲𝗳𝗶𝘁𝘀: After implementing visual management, here’s what happened: → Setup times decreased by 30% - workers knew exactly where to find tools. → Defect rates dropped by 25% - issues were flagged in real-time. → Production flow improved - bottlenecks were spotted early and resolved fast. → Team engagement increased - workers had clarity and ownership over their workspaces. A well-organized Shop Floor doesn’t just boost efficiency - it creates a culture of accountability and continuous improvement. "A chaotic workspace creates a chaotic workflow." Clear visuals aren’t just about organization - they’re about empowering people to perform at their best. How have you used visual management in your workplace? Looking forward to your insights! Wishing you a productive and focused Monday! - Chris Clevenger #Manufacturing #VisualManagement #ContinuousImprovement #LeanLeadership #Productivity

Don’t Automate Complexity... Simplify and Error-Proof Instead When problems arise, it’s tempting to think automation is the magic fix. But automating a broken or complex process just means you’re speeding up the production of errors. The smarter approach? Simplify the process and error-proof it (Poka Yoke) before thinking about automation. Here’s why simplification often beats automation and how you can apply it. Why You Should Simplify Before Automating: 1️⃣ Faster, Cheaper Improvements Simplifying a process through standardization and removing unnecessary steps often solves problems more quickly and at a lower cost than automation. 2️⃣ Avoid Automating Waste If your process is full of waste (like waiting, overprocessing, or rework), automating it only speeds up inefficiency. Fix the process first, then think about automation. 3️⃣ Built-In Error Proofing With Poka Yoke solutions (like jigs, fixtures, or guides), you can design processes to prevent errors from happening in the first place—without needing expensive sensors or software. 4️⃣ Flexibility and Adaptability Simplified processes are easier to adjust and improve, while automated systems can be rigid and costly to change once implemented. How to Simplify and Error-Proof a Process: 🔍 Map the Current Workflow: Identify unnecessary steps, bottlenecks, and areas prone to errors. ✂️ Eliminate Waste: Remove any steps that don’t add value to the product or service. 📋 Standardize Work: Create clear, repeatable instructions that everyone can follow. 🔧 Introduce Poka Yoke: Physical Error-Proofing: Use jigs, fixtures, or alignment guides to prevent incorrect assembly. Visual Cues: Use color-coded labels or visual templates to guide operators. Sensors or Alarms: Only when needed, use low-cost technology to detect errors in real time. Example of Simplification and Poka Yoke in Action: A warehouse team was dealing with frequent errors when picking products for orders. Instead of implementing a costly automated picking system, they: 1. Introduced a color-coded bin system (Poka Yoke) to help operators select the correct items. 2. Simplified the picking route to reduce unnecessary walking and waiting time. Result: Picking errors dropped by 80%, and productivity increased by 15%—all without expensive automation. When to Consider Automation: Once the process is simplified and stabilized with minimal variation, automation can enhance speed and efficiency. But it should support an optimized process, not mask its problems.

Manufacturing processes are often plagued by inefficiency.   Here's why:   Manufacturers cling to old batch habits. ___   Batch Production is a traditional manufacturing method where identical or similar items are produced in batches before moving on to the next step.   Some manufacturers argue that large batches balance workloads and minimize changeovers.   But data often shows otherwise.   Overlong production runs cause overproduction. Operators lose focus working on large batches while equipment drifts out of standards between changeovers.   Main drawbacks:   -Piles of WIP inventory waiting for the next step -Defects hide among the batches -Inefficient space management -Uneven workflow -Long lead times   Those lead to:   -Some stations being overloaded, others waiting -Low responsiveness to customer demand -More scrap and rework -Higher carrying costs -Facility costs up   Switching to One-Piece Flow can bring relief.    Workstations are arranged so that products can flow one at a time through each process step, making changeovers quick and routine.   Main advantages:   +High customer responsiveness +Minimal work-in-process inventory +Quality issues are detected immediately +Reduced wasted space and material handling +Easy to level load production to match takt time   The selection between batch processing and one-piece flow can significantly impact quality, productivity, and lead time in a manufacturing process.   P.S. Some case studies show improvements in labour productivity of 50% or more. Lead times can drop by 80%. And quality can approach Six Sigma.

Toolbox in TPM/Lean : SMED Explained SMED (Single-Minute Exchange of Die) is a technique to reduce equipment changeover time less than 10 minutes. It is a critical tool to improve operational efficiency by minimizing downtime during transitions between production/process tasks. Key Features 1. Purpose:   - Reduce setup/changeover time to improve machine availability and productivity.   - Support Lean principles like JIT production by enabling quick shifts between products or processes. 2. Integration with Efficiency:   - SMED aligns with the goal of maximizing Overall Equipment Effectiveness (OEE) by reducing downtime, one of the major equipment losses. 3. Philosophy:   - Separate changeover tasks into:     - Internal tasks: Activities that require the machine to be stopped (e.g., replacing parts.     - External tasks: Activities that can be performed while the machine is running (e.g., preparing tools). Steps in SMED Implementation 1. Observe the Current Process:   - Analyze the existing changeover process to identify inefficiencies. - If you dont have any standard select most efficient videotaped setup   - Example: Record video of a die change on a press machine. 2. Separate Internal and External Tasks:   - Identify which tasks can be done while the machine is running (external) and which require it to stop (internal).   - Example: Prepare tools and materials externally before stopping the machine. 3. Convert Internal Tasks to External Tasks:   - Modify workflows so more tasks can be performed without stopping the machine.   - Example: Preheat molds or stage materials in advance. 4. Streamline Internal Tasks:   - Simplify and optimize internal tasks to minimize time by using ECRS Technique, will be explained separately   - Example: Use quick-release clamps instead of bolts. 5. Standardize and Document Procedures:   - Create SOPs for consistent execution of changeovers.   - Example: Develop visual guides for operators. 6. Train Operators and Monitor Progress:   - Train staff on new procedures and track improvements in setup times.   - Example: Use OEE metrics to measure reductions in downtime. Benefits - Reduces downtime caused by long changeovers. - Increases equipment availability and OEE. - Enables smaller batch sizes, reducing inventory and lead times. - Improves flexibility in MEETING CUSTOMER DEMANDS for varied products. - Minimizes waste by eliminating unnecessary steps in the setup process. SMED and TPM - SMED enhances TPM's focus on reducing equipment losses by addressing setup and adjustment losses directly. - It supports TPM's goal of empowering operators through training and continuous improvement. - Together, SMED and TPM help achieve Lean goals like waste reduction, higher productivity, and improved customer satisfaction. By implementing SMED, organizations can create more agile production systems that respond efficiently to changing market demands while maintaining high levels of equipment effectiveness.

Procurement can cut out weeks of excess buffer stock and reduce lead times with end-to-end PO visibility and better supplier collaboration. Here’s how you do it: 1. Review Each Stage of Your PO Lifecycle Deep dive into your entire PO lifecycle, from order creation through to delivery. Are there any blockers you've neglected? This is the only way to pinpoint every single inefficiency and resolve them. Take your PO creation cycle, for example. Are you constantly waiting on approvals? This needs to be as short as physically possible to make sure you don't eat into any of that time that you've allowed for delivery of your product. 2. Streamline Collaboration Humans run supply chains yet 80% of the supply chain visibility problem is due to unstructured communication. Good relationships and streamlined communication are absolutely critical to make your job less stressful. A single channel to document all communications is needed. One where other teams can come in, collaborate and get visibility over what’s happening to the order. 3. Use Real-Time Data Use tools that offer real-time insights into your supply chain to take the guesswork out of your job. For this, digitizing your workflow is always the first step forward. 4. Negotiation & PO Dispatch After you issue a PO, it's important your supplier confirms receipt of your PO. If your supplier comes back to you with price, quantity or delivery date changes after a PO has been issued, how are you making sure these changes make it back into your ERP after you've approved the changes? And how are you approving these changes? Manually via multiple emails? Using software that automates PO acknowledgement reminders and PO delivery reminders several days before an order is due and a platform that allows you to communicate with your suppliers in real time vs. relying on emails and spreadsheets can increase productivity, reduce errors and ensure data accuracy. 5. Delivery & Quality Check Did your supplier deliver your order On Time In Full (OTIF) or is there a partial coming later? Make sure you have a process in place at your facility to access your newly received parts/materials to ensure there's no obvious quality issues. And if there is an issue, how are you documenting it and informing your supplier of the replacements needed?

Boost Efficiency with an Automatic Bag Slitter & Loader: Transforming Mixer Loading for Faster Batches and Reduced Product Loss In the fast-paced world of industrial mixing, optimizing efficiency is key to staying ahead. The introduction of an Automatic Bag Slitter & Loader can revolutionize your mixing process, significantly cutting down batch times and minimizing product loss. Let's delve into how this innovative solution can streamline your operations and elevate your production capabilities. 1. Accelerated Loading Process: Streamline Your Mixer Loading with Precision and Speed Say goodbye to time-consuming manual processes. The Automatic Bag Slitter & Loader is designed to swiftly and accurately handle the opening and loading of bags, ensuring a seamless and rapid material input into your mixer. This accelerated loading process translates to a substantial reduction in overall batch times, allowing you to increase production output without compromising quality. 2. Precision and Consistency: Ensure Uniform Ingredient Distribution for Optimal Results Achieve unparalleled consistency in your mixtures by embracing the precision offered by the automatic bag slitter and loader. The technology ensures uniform dispensing of ingredients, eliminating the risk of uneven mixing. This not only enhances the quality of your products but also reduces the need for post-production adjustments, saving both time and resources. 3. Minimized Product Loss: Preserve Your Resources with Minimal Waste One of the most significant advantages of incorporating an Automatic Bag Slitter & Loader is the reduction in product loss. The system is designed to handle materials with care, minimizing spillage and waste during the loading process. This not only contributes to cost savings but also aligns with sustainable manufacturing practices, making your production process more environmentally friendly. 4. Operator Safety and Resource Allocation: Empower Your Workforce with Enhanced Safety Measures By automating the bag slitting and loading process, you prioritize the safety of your workforce. Operators can focus on overseeing and optimizing the production line, reducing the risk of accidents associated with manual bag handling. Additionally, with the automatic system in place, labor resources can be reallocated to more strategic and value-added tasks within your facility. 5. Integration and Customization: Tailor the Solution to Fit Your Unique Requirements The flexibility of the Automatic Bag Slitter & Loader allows for seamless integration into your existing production line. The system can be customized to accommodate various bag sizes and types, ensuring a perfect fit for your specific needs. This adaptability ensures a hassle-free transition to a more efficient and productive mixing process. Come see the PerMix difference https://lnkd.in/gSKm-TBF