Good Connections Magazine

G O O D CO N N E C T I O N S | W I N T E R 2 0 1 5 8 Comprehensive Plant Audits Boost Production Efficiency By Jack Van Cleave, Senior Manufacturing Consultant, Alpine A lpine recommends that truss manufacturers conduct regular, comprehensive plant efficiency reviews to improve productivity. The goal of these audits is to increase board feet production rates and evaluate production effectiveness. Audits also help prioritize equipment replacement sched- ules to optimize investments. These audits can be performed by equipment suppliers or independent contractors. There are many areas that can be examined in a manufacturing review, starting from when the order is received until the finished goods are shipped. What happens when your salesman receives the order? This is the point where the manufacturing process actually begins – not when the plant starts building the product. How do you schedule the ship date? Do you know how many orders can be completed in a day? What is the best way to cut, stack and stage an order? Do you track production so you know how much each jig can produce and can schedule it without overtime hours that reduce profits? The days of building stock trusses for inventory are long gone. In most plants, the average run or setup is now 2.1 trusses. Years ago, we typically built 22 commons and two gables. While every plant is different, each is also alike in what it actually does. We are essentially in the material handling business, and the plant that touches a piece the least in the shortest amount of time is often the most productive one. Comprehensive plant audits help customers maximize their productivity. Customers who have held reviews, followed the advice and implemented new procedures have shown remarkable efficiency improvements. Customer Examples One customer was operating at 43 board feet per man-hour prior to performing a plant evaluation. After completing the evaluation and making changes in equip ment and manufacturing processes, pro duction increased to 63 board feet per man-hour after six months and 73 board feet per man-hour after 12 months. Enhanced productivity and efficiencies save money and go straight to your bottom line. Another customer reported: As noted in the report, we do not track production by board feet. We track by sticks (a stick is any piece of lumber or steel, regardless of size). Following is a snapshot of the past 12 months – the first six are pre-audit, the second six are post-audit: 6-Month Period Average Sticks Per Man-Hour August 2012 through January 2013 Wood: 14.83 Steel: 8.65 February 2013 through July 2013 Wood: 19.15 Steel: 11.41 (+29 percent) (+31 percent) Beginning vs. Current Production Average Sticks Per Man-Hour January 2013 (month prior to audit): Wood: 13.77 July 2013 (post-audit): Wood: 23.46 (+70 percent) Making the Change Customers often know what they should do to enhance plant efficiencies, but need a reminder and assistance to get them started. Change is difficult, but now is the time to look at bad produc tion habits that may have developed when business was slow and you were just trying to survive. Review how you are doing things and where you can implement changes to increase your productivity. Start with small wins and your employees will buy into the process. Then it becomes much easier to make additional changes. Good luck and continue to strive for improvement. Be sure to ask us how we can assist you. n Jack Van Cleave joined Alpine in 1992 and has extensive experience with component manufacturing equipment and plant layout. He is based in the Grand Prairie, Texas, office. PLANT PRODUCTIVITY SAFETY TIP Never wear loose clothing, dangling jewelry or items with hanging strings, ties or belts around automated equipment. Any of these items can get caught in rotating assemblies such as blades, belts or gears and throw you off balance before you can react. You may be pulled into the machine, leading to severe injury. For additional safety, stand comfortably with your feet far enough apart for good balance, and wear footwear with non-slip soles. Source: Woodcraft Supply LLC (www.woodcraft.com)

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