Role
Production: where do we lose time or volume?
Production needs to see where the time goes and what to fix first, while there is still time to do something about it.
Questions and decisions
From question to evidence
Each question needs certain evidence to be answered. Together they lead to what the role needs afterwards.
Production asks
What is needed to answer
Afterwards
Question 1: "Where do we lose time or volume?"
Needs: Status and stops per machine
Question 2: "What should be fixed first?"
Needs: Reasons from a shared list
Question 3: "Does the quality problem affect production?"
Needs: The same evidence as quality
Afterwards
Losses that shrink over time, and improvements that can be followed up.
Situations
Where the questions arise
Each situation is described once. Here you see the question and the decision for this particular role.
Situation
Values creep towards the limit
Read about the situation"Will this lead to a stop or scrap if nobody acts?"
Decision: Whether to schedule a tool change.
Situation
The machine is down
Read about the situation"Where do we lose the most time, and what should be fixed first?"
Decision: Which losses are prioritised.
Situation
Changeover to the next part
Read about the situation"How long do changeovers take, and where does the time go?"
Decision: Which changeovers to improve.
Situation
Incoming material does not meet requirements
Read about the situation"Which orders are affected, and can we keep running?"
Decision: Whether production should be rescheduled.
Behind the questions
Where the time goes
A stop becomes useful only when it has a time, a reason and a decision. Summed over weeks, production monitoring shows where the time goes, and often that stops without a reason are the largest item.
What does it take for a stop to be improved, and not just forgotten?
Illustration · Example dataMachine status during one shift
01 · Machine
Stop
The machine stops at 08:05. The time is recorded from the machine signal.
02 · Operator
Reason
The reason is entered at the machine, from a shared list: material change.
03 · Operator
Decision
Can we handle it ourselves, or do we need a setter or maintenance?
04 · Operator
Action
The material is changed. The setter is not needed.
05 · Machine
Restart
The machine runs again at 08:17. The stop is closed with a reason.
06 · Production, engineering
Follow-up
Stop time per reason over weeks shows what to fix first.
Follow-up: stop time per reason, four weeks
- Unknown reason55 min
- Material change42 min
- Waiting for setter31 min
- Tool change18 min
A stop becomes useful only when it has a time, a reason and a decision. The largest item in the follow-up is often stops without a reason.
Other roles, same situations
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