IDEAS

  • MANUFACTURING & SUPPLY CHAIN
    • Pre-Production Validation
      • Analyze potential improvements to factory utilization
      • Setup Tooling, IQA, etc...
      • Define dock-to-stock; point-to-point, etc. distribution systems to minimize time waste
      • Establish how to manage in-process inventory
      • Establish Set-up or change-over processes for production equipment
      • Establish product inspection and testing; equipment calibration and testing;  overhead to support above
      • Reduce training costs {1, 2, 4, 5, 6, 10, 14, 15, 16}
      • Confirm manufacturing processes {1, 4, 5, 7, 12, 14, 15, 16}
      • Product Validation (see above) {2, 4, 5, 6, 8, 9, 10, 11, 13, 14, 15, 16}
      • Set up service and support operations {1, 4, 5, 8, 9, 10, 14, 15, 16}
      • High/low volume considerations {3, 4, 5, 6, 7, 8, 12}
      • Partner with suppliers  and establish supply chain and procurement processes  {1, 3, 4, 5, 6, 7, 8, 12, 13, 14}
      • Negotiate component, subassembly, support costs {1, 3, 4, 5, 6, 7, 8, 12, 13, 14}

    • Production & Distribution and INTENDED support
    • Lower the total cost of manufacturing (Lean Production Cost Reduction)

      • Improve factory utilization
      • Determine and reduce the asset drain of work-in-progress
      • Product Line Rationalization Cost Reduction
      • Improve Logistics and Supply Chain
      • Reduce inventory (Inventory is not an asset)
      • Reduce inventory & shipping insurance
      • Eliminate WIP inventory carrying cost
      • Reduce non-moving WIP
      • Increase response times
      • Optimize warranty testing
      • Implement JIT if appropriate
      • Increase response of systems
      • Improve handling and storage of finished goods
      • Improve picking and shipping releases and orders
      • Reduce rework (changes), bad components (waste) {3, 4, 7, 8, 12}
      • Minimize QC and other testing of product (improve quality, minimize overhead to support testing) {3, 4, 5, 7, 8, 12, 16}
      • Partner with suppliers to optimizing procurement efficiency (supply chain improvements) {1, 3, 4, 6, 7}
      • Volume production cost analysis {1, 3, 4, 5, 7, 8, 12, 13}
      • Reduce reliability & Quality costs: bad quality, scrap, rework, and other non-value-adding activities {1, 3, 4, 7, 12, 13}
      • Analyze supply of raw vs. produced materials {2, 3, 4, 5, 7, 12, 13}
      • Minimize set-up and change-over of production and test equipment {1, 3, 4, 5, 12}

     
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    2008, Richard M. Haney, CMT Group
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