Micro-stoppages are brief interruptions during production. They can be caused by power outages, process inefficiencies, material handling issues, environmental factors, operator error, or equipment malfunctions.
Although micro-stoppages might last a few seconds, the interruptions quickly add up. The results include impacted production schedules, significant losses of efficiency and productivity, and potential missed deadlines. These factors increase manufacturing costs and reduce the bottom line.
Identifying and eliminating these hidden time wasters on the production floor elevates efficiency and productivity, helps meet deadlines, and reduces expenses. Environmental control, improved material handling processes, production process optimization, regular equipment maintenance, and effective training and refresher courses can help.
Causes of Micro-Stoppages on the Production Floor
Common causes of micro-stoppages on the production floor include:
- Power outages that temporarily halt the production line.
- Process inefficiencies due to poor planning, lack of standardization, or inefficient workflows that lead to delays and rework.
- Material handling issues such as poor inventory management, improper storage, or incorrect labeling that require corrective action and lead to production delays.
- Environmental factors such as temperature, humidity, and lighting that lead to operator error or cause the equipment to malfunction.
- Operator error due to ineffective training, fatigue, distraction, or human error, such as improperly setting up the equipment, misplacing tools, and forgetting to perform routine checks.
- Equipment malfunctions due to improper use, wear and tear, or lack of maintenance, such as misaligned parts, faulty wiring, and jammed sensors.
Methods to Resolve Micro-Stoppages on the Production Floor
Methods to resolve micro-stoppages on the production floor include:
- Environmental control over the temperature, humidity, and lighting to optimize conditions for the equipment and operators.
- Improved material handling processes such as conducting regular inventory checks, properly labeling materials, and storing materials in the correct locations.
- Production process optimization such as identifying bottlenecks to improve efficiency.
- Regular equipment maintenance to identify and resolve issues before they occur.
- Effective training and refresher courses to develop operator knowledge and skills and minimize errors.
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