Insights - Manufacturing Excellence

TWI for the 21st Century – Are Coaching Networks the future?

The US established the Training within Industry (TWI) Services as part of the War Manpower Commission in the summer of 1940.  At the time the US faced a significant challenge – how to increase industrial production of wartime materials while the industrial workforce was abroad, fighting the war.

4 mistakes to avoid when writing work instructions

In our daily lives, we come across examples of work instruction all the time - we follow cooking recipes, search for ‘How to’ videos online, try to understand the  user manual when setting up a new home appliance.

Why training is failing the frontline workforce

It is estimated that deskless workers make up 80 percent of the global workforce. Those are the workers at the organisational frontline:

Visual Work Instructions: What are the best devices and user interfaces?

In our article dedicated to The Benefits of Visual Work Instructions, we looked at how a digital, multi-media upgrade of Standard Operating Procedures can have a far-reaching positive impact on the shop floor – from improved safety and quality, to reduced training costs.

What are the benefits of Visual Work Instuctions?

Do you have a bunch of cookbooks in your kitchen and yet, whenever you cook, you search online for a recipe with step-by-step images? Have you ever fixed a home appliance, or resolved a plumbing disaster, or revived your car in the middle of nowhere by following a YouTube video rather than the paper manual? Have you ever video-called a friend who knows how to fix or do something that you’re struggling with and followed their guidance? What you’ve searched for in any of those situations are visual work instructions.

The challenges of the changing manufacturing workforce and how to address them

Some might say that the manufacturing industry is facing a perfect storm in terms of workforce instability:

• an ageing workforce putting valuable tribal knowledge at risk

What are the benefits of standard work?

What is Standard Work?

Put simply, standard work is all about defining and implementing the most effective and efficient way to deliver value.

Overall Equipment Effectiveness: How to calculate and improve your OEE score

The term Overall Equipment Effectiveness (OEE) was coined in the 1980s by Seiichi Nakajima and has since been used in Total Productive Maintenance to measure the total productivity of a machine or product line.

What are the benefits of a paperless factory (or how paper-based systems are hindering manufacturing excellence)

Let’s look at two shop floors – one depicted in the nineteenth century and the other photographed in the twenty-first.

What is the operator skillset required for Industry 4.0?

We are amidst “the next phase in the digitization of the manufacturing sector” also known as the Fourth Industrial Revolution or Industry 4.0. Most definitions focus on the technological disruptors behind it such as:

How to make continuous improvement work for your organisation?

Nearly half of organisations’ attempts to implement continuous improvement fail. We look at what might be the underlying causes and how fixing the feedback loop between planning and frontline execution can increase the success rate of adopting continuous improvement.

Supplier Performance Management:  What are the benefits of a collaborative approach?

Whether managing a multi-tier supplier network or a handful of local suppliers, manufacturers are likely to face issues with supplier performance.

How to improve your ‘First Time Right’ score in 5 steps

Imagine that you are having a new oven fitted in your kitchen.

Would you:

Have it fitted the right way the first time around, ensuring that it is perfectly functional from day one and works without a fault thereafter?

How to upskill your shop floor workforce in 5 steps?

In 2013, not long after the term Industry 4.0 had been coined, an Oxford study predicted that 47 per cent of US employment was at risk of being automated out of existence1. Since then many pessimistic (and technophobic) accounts have followed suit.

How to eliminate manufacturing losses with remote equipment monitoring

Industry 4.0 is transforming the way manufacturing operations are executed and monitored. Manufacturing companies are turning to new technological capabilities.

What are the Six Big Losses in manufacturing and how to eliminate them

Developed in 1971 at the Japanese Institute of Plant Maintenance, the Six Big Losses in manufacturing have been used as a way to categorize equipment-based losses and maximize overall equipment effectiveness.

Underpinning the 10 pillars of World Class Manufacturing with digital technology

The affordability and quality of a product are fundamental determinants of customer satisfaction.

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