Detect Defects before they Affect...

Improving the production process is streamlining and integrating the production system to achieve an efficient and simple product flow. Continuous improvement implies that the manufacturing system will continue to include both process and product improvement. The process of continual improvement is aimed at reducing the need for gate inspection, rework, scrap, and test. IPC is an economical tool to minimize these costs. The results of using IPC is the prevention of defects before they occur.

Planning the production process

A valuable tool in planning the production process is to isolate and define the elements that make up a production system as building blocks.

Product flowchart

In a flowchart, the building blocks of the production process can be analyzed for significance of impact to the production system and points requiring improvements.

Performance measures

To achieve continued improvement, a company must measure the performance levels of its smallest processes against its optimum values. This is accomplished by having performance measures visible to all levels in a company. The use of control charts is one of the best ways to show the collected performance measures.

Floor plan layout

The design or layout of the production line can be considered after the specification has been evaluated and matched to the required production process. A JIT production line uses multi machine manning. The advantage is not actually the reduction in labor cost rather to reduce the number of support systems.

Balancing production capacity and setup-time.

The setup-time can be minimized by the use a fast production process and only produce parts on demand. If the setup-time is a factor, the preferred process is to apply a smaller and slower production method that has the ability to produce the daily requirement in a more continuous production movement.

Material delivery

By delivering material directly to the production line on at least a daily basis optimize materials delivery for a JIT system. Two primary requirements that influence material delivery and inventory concerns are material quality and availability.


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