Increasing Production: A 200% Increase in SMP Line Output”
S – Situation: In our SMP line, we were grappling with a substantial backlog that had reached 45,000 units. To address this issue, I recognized the need to identify and overcome our production barriers.
T – Task: My primary task was to gain a deep understanding of the obstacles hampering our production and find a solution to significantly increase efficiency.
A – Action: Here are the key actions I took to address this challenge:
- Data-Driven Insight: I developed a daily tracker to monitor our main bottleneck in real-time. This tracker allowed us to record when equipment failures caused testers to stop working.
- Enhanced Collaboration: I leveraged this data to facilitate communication and collaboration between CTDI and our operations team. It became a Data-Drive tool to address the issues together.
- Root Cause Analysis: By using this data, we conducted a detailed root cause analysis. It revealed that the primary impediment to our production was not software updates or problematic devices, but equipment malfunctions.
- Innovative Proposal: Armed with this insight, I proposed a change aimed at resolving the equipment-related issues. This change was designed to increase our production efficiency.
R – Estimate Result: The outcomes of these actions will nothing short of remarkable:
- Production Boost: The proposed changes will lead to an astonishing 200% increase in production output. By addressing the root cause of equipment malfunctions, we will able to significantly enhance our efficiency.
- Effective Collaboration: The real-time tracker and the shared data fostered effective collaboration between CTDI and our operations team, ensuring that both groups were aligned and working towards the same goals.
- Operational Clarity: The data-driven insights provided clarity about the main issues affecting our production. This clarity allowed us to prioritize resources and efforts effectively.
This success story underscores the transformative power of data-driven decision-making, effective collaboration, and a targeted approach to addressing root causes. By identifying and addressing equipment malfunctions as the primary barrier, we not only resolved the backlog issue but also achieved an impressive 200% increase in production efficiency, highlighting the tangible benefits of proactive analysis and optimization in the business intelligence field.
The best part this approach can scale to other lines.
