This post has been de-listed
It is no longer included in search results and normal feeds (front page, hot posts, subreddit posts, etc). It remains visible only via the author's post history.
Hello all, hoping you guys can help me with a few ideas!
I am currently working in a manufacturing company where we make food processing equipment such as bread and confectionary machines. This company has historically had a poor future production engineering where not many process improvement initiatives have been done and are seeming quite new to the business.
For a bit of a back story, we have recently been purchased by a bigger company as opposed to being privately owned like before, and the company which has bought us out is some very American, corporate business. The business gets in raw materials such as flat plate, SHS/RHS, etc. and manufacture them into fully operating machines. We design, plan, fabricate, machine, assemble and continuously support our customers with all future spares and services. - I am a fabrication based production engineer who has been in the role for about 5 years after finishing a welding/plate metal fabrication apprenticeship.
I have been tasked with coming up with 3 (minimum) process improvement initiatives. I have come up with one for DMR workflow through the business (Damaged Material Requisitions) which helps highlight material issues which are currently being driven through the business. I have colour co-ordinated the paperwork and have highlighted any operation or material additions to the top of the travellers which go around the business with the manufactured components to make it easier for material transportation or for section leaders to see what work additions have been added. - Every time i search for idea elsewhere, it gives me more broader ideas such as completing 5S or Kaizen events (which we are already doing, but I am not allowed to pick a point which has been raised in one of these events) - I was looking for more precise ideas such as new working methods or a new process to aid manufacture or simplify existing ones.
If anyone is working in a similar manufacturing company, or role, what are some good ideas you have incorporated into your business, and how much of an impact did they make?
Chemical engineer and industrial engineer by education.
After my undergrad in chemical engineering, I designed large vessels for specialty chemicals, O&G, petrochemicals, fragrance, and then developed bulk powder system for plastic, which ultimately found more success in food industry, specifically baking operations, which led me more and more deeper into the food industry.
For your standardized equipment (I am assuming the company has standardized equipment which has been designed and done, and is not custom built for each customer) you need to bring down the variability in BillofMaterials (BoM). This method won't work for custom designed and built equipment. Once variability in BoM is brought down to a specific level, it will become more profitable to hold inventory of inputs (steel plates, pumps, paddles, bushings, pipes, tubing etc.) rather than having an inventory of standardized equipment. From a small number of basic ingredients you can make multiple different dishes kinda theory, like Taco Bell. For example, instead of having 6 different pump sizes across 10 standardized equipment and each having 5 different sizes, so ultimately 50 standardized equipment, only have 3 different pump sizes. Standardize the pipe diameters and thickness you use, to 3-4 different types. Standardize the stand types for each, so each stand is same, other than it's height or width or length. Similarly, on the control box side, standardize the wire diameters/gauges, ferrule colorings (if applicable), relays, and if possible the PLC computer too. HMI screens are the easiest to standardize. Once you bring down the total variability of individual components low enough, it is easier and cheaper to stock these basic ingredients, and be able to quickly fabricate required dishes.
Nozzles and nozzle paddings. I'm assuming there are not many nozzle types or are there? And if there are, to ease the cleaning procedure, they're clamp type nozzles instead of flange type nozzles? If there is anything high pressure, there will be nozzle paddings. Or if anything's acidic or basic enough, the nozzles will probably be of 304L/316L while other nozzles will be 304/316. The usage of nozzle pipes and others is small enough sometimes that it makes more sense to make everything of the L variant, rather than storing different kinds of nozzle pipes. Obviously, a strong cost estimation is needed.
Welding, rolling, straightening, plate cutting, acid cleaning, buffing, passivation - batching, order pooling and scheduling always has a better more efficient way of doing where savings in changeovers or labor can be achieved. Don't schedule repeating stuff of carbon steel and stainless steel. First do carbon steel all of it, and then go to stainless. Acid cleaning and passivation is horrible to do, so one batch/order should be as large as possible, assuming you do it in-house.
I don't know if these are possible at YOUR place of work, but I'm assuming they should be.
Subreddit
Post Details
- Posted
- 7 months ago
- Reddit URL
- View post on reddit.com
- External URL
- reddit.com/r/manufacturi...