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Will You Add? - TPM and Lean Production, is It Worth the Effort?
We all have recollections of historical dates of significance. So as you plan out your yearly calendar, have a little fun with what is going on in the outside world. Look for clever dates and innovation memorials that you can use as a marketing tool. Not only can you use these little tidbits to amuse yourself, you can also use them to reconnect with friends, colleagues, associates, bosses, potential employer, and reporters.March 15th was the day Julius Caesar was given the warning of impending doom. He, as history connotes, ignored the warning. If you are Irish, St. Patrick's Day is a big one and it is just around the corner. Also, did you know tha
An example: A plant produces 10,000 units per year with an OEE-ratio of 50 percent. After improvement, the project team estimates that it will be possible to reach an OEE-ratio of 80 percent. This means that they will be capable to produce
10,000*80/50 = 16000
units in the same facility without investments and with the same manning as before.
Can the increased capacity be used to increase sales?
One important question is if the
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"We should implement Lean Production and TPM in our plant", he says. "This will make our production more reliable and increase our delivery accuracy".
The MD is paying attention but is not yet convinced. He wants to put the ideas to a test.
"Looks interesting", he says, "Please come back with a good calculation of the Return on Investment so that we can see if it fits into next year's budget."
This is where the story might end. How could you possible estimate costs and benefits from such advanced management techniques as TPM and Lean Production? These concepts are known to be difficult to plan in advance, and they require a mind-shift for everybody in the facility.
Well, it may be difficult but you have to do the calculation anyway. Arguments as "we have to do this" or "everybody else is doing it" are just not convincing enough.
A change project must be looked upon as an investment that will come with initial costs and hopefully bring something back in return. This is no different from any other investments. If you can not give an educated guess on its financial impact, there is a big risk that the project might not be given the necessary resources for what it needs to succeed. Even if the financial impact of important factors such as shorter lead times and better delivery accuracy are not known, we need to describe how this project will raise profits in the company.
To give an answer to these important questions we have put together some simple guidelines for you to use, and if you prefer, a free calculation tool that you may use to do your own estimations.
What will the costs be?
The main cost will consist of:
Training and Consultancy
No successful implementation of TPM and Lean Production has succeeded without the help of experienced professionals. You will have to train your employees and you need support in your project team. A good estimation is a yearly cost of $100.000 per 100 employees involved
Increased initial maintenance costs
Elimination of manufacturing wastes and implementation of improvement ideas are likely to increase the maintenance costs. Expect maintenance to increase up to 20% the first year, but with it stabilizing at a level less than today after one to two years.
Project team members
You will need people to run the project. Project management and coaching equals to about one full-time coordinator per 100 employees in the facility
Benefits
Increased Overall Equipment Efficiency (OEE) is the main factor that may be used to approximate the return on the efforts. Simply speaking, the OEE is the ratio of the facility's actual output compared to the theoretical output that would be possible if the machinery was run at full speed every minute, without break-downs, lack of raw material, quality losses or set-ups. As the OEE-ratio is a direct reflection of your plant's capacity, it may be used to calculate the future productivity after improvements.
An example: A plant produces 10,000 units per year with an OEE-ratio of 50 percent. After improvement, the project team estimates that it will be possible to reach an OEE-ratio of 80 percent. This means that they will be capable to produce
10,000*80/50 = 16000
units in the same facility without investments and with the same manning as before.
Can the increased capacity be used to increase sales?
One important question is if ther
It is my opinion that men and women start to become great when they begin to listen to their inner voice, their intuition.When you begin to use it regularly and systematically, there is virtually nothing that you can not accomplish.You may experience your intuition as a gut feeling, as an inner sense of what is right and wrong for you.Sometimes your intuition manifests itself as a hunch or an inspiration.Often, it comes as a flash of insight. Your intuition leads you to new ideas, concepts, and breakthroughs.And even sometimes an intuition insight will enable you to see a problem from a new perspec
Well, it may be difficult but you have to do the calculation anyway. Arguments as "we have to do this" or "everybody else is doing it" are just not convincing enough.
A change project must be looked upon as an investment that will come with initial costs and hopefully bring something back in return. This is no different from any other investments. If you can not give an educated guess on its financial impact, there is a big risk that the project might not be given the necessary resources for what it needs to succeed. Even if the financial impact of important factors such as shorter lead times and better delivery accuracy are not known, we need to describe how this project will raise profits in the company.
To give an answer to these important questions we have put together some simple guidelines for you to use, and if you prefer, a free calculation tool that you may use to do your own estimations.
What will the costs be?
The main cost will consist of:
Training and Consultancy
No successful implementation of TPM and Lean Production has succeeded without the help of experienced professionals. You will have to train your employees and you need support in your project team. A good estimation is a yearly cost of $100.000 per 100 employees involved
Increased initial maintenance costs
Elimination of manufacturing wastes and implementation of improvement ideas are likely to increase the maintenance costs. Expect maintenance to increase up to 20% the first year, but with it stabilizing at a level less than today after one to two years.
Project team members
You will need people to run the project. Project management and coaching equals to about one full-time coordinator per 100 employees in the facility
Benefits
Increased Overall Equipment Efficiency (OEE) is the main factor that may be used to approximate the return on the efforts. Simply speaking, the OEE is the ratio of the facility's actual output compared to the theoretical output that would be possible if the machinery was run at full speed every minute, without break-downs, lack of raw material, quality losses or set-ups. As the OEE-ratio is a direct reflection of your plant's capacity, it may be used to calculate the future productivity after improvements.
An example: A plant produces 10,000 units per year with an OEE-ratio of 50 percent. After improvement, the project team estimates that it will be possible to reach an OEE-ratio of 80 percent. This means that they will be capable to produce
10,000*80/50 = 16000
units in the same facility without investments and with the same manning as before.
Can the increased capacity be used to increase sales?
One important question is if the
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To give an answer to these important questions we have put together some simple guidelines for you to use, and if you prefer, a free calculation tool that you may use to do your own estimations.
What will the costs be?
The main cost will consist of:
Training and Consultancy
No successful implementation of TPM and Lean Production has succeeded without the help of experienced professionals. You will have to train your employees and you need support in your project team. A good estimation is a yearly cost of $100.000 per 100 employees involved
Increased initial maintenance costs
Elimination of manufacturing wastes and implementation of improvement ideas are likely to increase the maintenance costs. Expect maintenance to increase up to 20% the first year, but with it stabilizing at a level less than today after one to two years.
Project team members
You will need people to run the project. Project management and coaching equals to about one full-time coordinator per 100 employees in the facility
Benefits
Increased Overall Equipment Efficiency (OEE) is the main factor that may be used to approximate the return on the efforts. Simply speaking, the OEE is the ratio of the facility's actual output compared to the theoretical output that would be possible if the machinery was run at full speed every minute, without break-downs, lack of raw material, quality losses or set-ups. As the OEE-ratio is a direct reflection of your plant's capacity, it may be used to calculate the future productivity after improvements.
An example: A plant produces 10,000 units per year with an OEE-ratio of 50 percent. After improvement, the project team estimates that it will be possible to reach an OEE-ratio of 80 percent. This means that they will be capable to produce
10,000*80/50 = 16000
units in the same facility without investments and with the same manning as before.
Can the increased capacity be used to increase sales?
One important question is if the
Have you considered buying store returns?Every wholesale buyer eventually comes across offers for store return merchandise.It’s a difficult decision wether should someone get involved with store returns.While the profit potential is definitely there, there are also adverse factors to consider.To start with we need to have a clear understanding of what store returns are.Most major retailers have a program where they accept returns from their customers.Keep in mind that the returned merchandise does not always have to be in its original packaging.For instance, one major retailer, allows returns of children’s
Elimination of manufacturing wastes and implementation of improvement ideas are likely to increase the maintenance costs. Expect maintenance to increase up to 20% the first year, but with it stabilizing at a level less than today after one to two years.
Project team members
You will need people to run the project. Project management and coaching equals to about one full-time coordinator per 100 employees in the facility
Benefits
Increased Overall Equipment Efficiency (OEE) is the main factor that may be used to approximate the return on the efforts. Simply speaking, the OEE is the ratio of the facility's actual output compared to the theoretical output that would be possible if the machinery was run at full speed every minute, without break-downs, lack of raw material, quality losses or set-ups. As the OEE-ratio is a direct reflection of your plant's capacity, it may be used to calculate the future productivity after improvements.
An example: A plant produces 10,000 units per year with an OEE-ratio of 50 percent. After improvement, the project team estimates that it will be possible to reach an OEE-ratio of 80 percent. This means that they will be capable to produce
10,000*80/50 = 16000
units in the same facility without investments and with the same manning as before.
Can the increased capacity be used to increase sales?
One important question is if the
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An example: A plant produces 10,000 units per year with an OEE-ratio of 50 percent. After improvement, the project team estimates that it will be possible to reach an OEE-ratio of 80 percent. This means that they will be capable to produce
10,000*80/50 = 16000
units in the same facility without investments and with the same manning as before.
Can the increased capacity be used to increase sales?
One important question is if there is a market for expansion. If so, the increased capacity may be used for increased sales. It is common that the company's market share might grow after implementing TPM or Lean Production. This is possible as improved delivery accuracy and shorter lead times make more sales possible even if the market is stagnant.
If expansion is not considered possible, the increased capacity may instead be used to lower the production costs. This is possible through
- less overtime
- fewer shifts
- fewer parallel production lines maintained and operated
The direct labor costs for production will therefore decrease as the OEE-ratio increases.
Your present and future OEE-ratio
Do you know your plant's present OEE-ratio? If so, is it accurately calculated? Often we see that some downtimes are deducted when OEE is calculated. This might be stops for planned maintenance, set-up times, and lack of personnel. The end result will be an OEE-ratio that looks better than reality.
If you do not know your present OEE-ratio, the easiest way to determine it is to use the free OEE - calculator at wcm.nu.
Then estimate what you consider a possible OEE-ratio after improvements. World Class companies reach 80-95% OEE, what is a realistic level for you?
Use the present and future OEE to calculate the future benefits. If you don't want to do the calculations by hand, try instead the free TPM and Lean - calculator at wcm.nu.
Et voil?! You have your Return on Investment calculation to present to your stake-holders!
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