How can you identify underperforming areas in your plant?

An effective approach to consider is the implementation of OEE (Overall Equipment Effectiveness) among the indicators, as it measures the availability/utilization of equipment, its performance, and the quality of its output. This method is particularly valuable because it connects multiple areas, including Maintenance, Supply Chain, and Quality & Engineering, fostering collaboration and process optimization.

Para identificar áreas de baixo desempenho, comece definindo indicadores de desempenho (KPIs) que reflitam as metas produtivas e permitam uma análise precisa. Avalie regularmente esses indicadores e compare-os com as metas para identificar desvios. Em seguida, realize uma análise de causa raiz usando ferramentas como o diagrama de Ishikawa ou os 5 Porquês, facilitando a compreensão dos problemas e a implementação de ações corretivas. Após aplicar as melhorias, monitore o desempenho para confirmar os resultados. Esse ciclo de definição, avaliação, correção e monitoramento contínuo é essencial para alcançar e sustentar a excelência operacional.

L’analyse comparative est essentielle pour évaluer la compétitivité et l'efficacité de votre usine. En comparant vos KPIs à des normes internes et aux benchmarks de l'industrie, vous identifiez objectivement les écarts de performance. Des outils comme les tableaux de bord permettent de visualiser ces données, mettant en évidence les points à renforcer pour fixer des objectifs de progrès concrets et atteignables.

An interesting approach would be to analyze elements of a process as if viewed in slow motion, mainly those that are often perceived as simple, routine, and unquestionable. Take, for example, the act of drilling a hole. When the button is pressed, electrical energy is activated, causing the mandrel to receive radial acceleration and transfer this motion to the fixed drill bit. By breaking down these steps, we may uncover hidden phenomena that could be the root cause of a specific issue or insight we are seeking.

L'analyse des causes profondes (RCA) est cruciale pour traiter les sous-performances de manière durable. En remontant à l'origine des problèmes, elle permet de prévenir leur récurrence. Les outils comme les 5 pourquoi, les diagrammes en arête de poisson et de Pareto facilitent l'identification des causes racines, optimisant ainsi qualité et efficacité.

La mise en œuvre de mesures correctives est essentielle pour éliminer les causes des sous-performances et éviter leur récurrence. Prioriser les actions selon leur impact, faisabilité et coût garantit une optimisation efficace. Le suivi par boucles de rétroaction permet d’évaluer les améliorations et d’ajuster les actions pour un rendement optimal.

L’évaluation continue et l’amélioration sont fondamentales pour maintenir la performance de l’usine. En mesurant l'efficacité des actions correctives, on ajuste les processus en fonction des résultats obtenus. Des outils comme les audits, les enquêtes et les cycles PDCA garantissent un alignement constant des opérations sur les objectifs.

Look deeply in your P&L, balance sheet and cash flow. The signals are there. Prices ok? Scrap ok? Debts ok? Some important things can be covered in " other costs". Working capital ok? Inventory crystal clear? Slow moving stocks ok? Fraud control ok?

In my view, to identify underperforming areas in your plant, you can consider implementing key performance indicators (KPIs) such as production output, efficiency metrics, downtime analysis, and quality control measures. Regularly monitoring these indicators can help pinpoint areas that may need improvement. Additionally, seeking feedback from employees involved in different processes and conducting thorough inspections can provide valuable insights into potential issues.