Material balancing

Material balancing is a great system to find “material leaks” where money goes to the drain whiteout anyone noticing it. It is similar to inventory counts that we do in warehouses but in this case we do not only count inventory but also the amount of inventory in WIP and we search for material leakages. This is a very easy to make system that help us save a lot of money.

Inventory management using Kanban

Kanban is a “magical” inventory management system. It requires no databases and no gadgets. Yet, it allows organizations with a lot of parts to manage them almost without much planning. It is very useful and I am recommending it every time it fits.
This post is all about the Kanban system, with examples and recipes on how to make it works.
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Formula compare – production efficiency

Sometimes the best way to improve the production is to look at the differences between what materials we planned to use ver. what we actually used. It supposes to be the same, but if you have more then 1 material that you can use as a substitute then probably your planned and actual cost per batch are not the same in some cases. That allows you to find places to do a major improvement. This post is not easy but very important.

Right first time: Using SPC to improve RFT

Starting production with the right parameters with low scrap and almost no time consumption is important for production efficiency.
RFT=right first time
RFT is a challenging task for most production organizations that produces many products/parts.
Using SPC is a good way to solve problems regarding RFT.
How can we find the parameter that we can improve, out of hundreds of products and dozens of parameters that each product has in its spec?

Material balancing – finding material leakage

In today’s organizations we have a lot of acquired items and raw materials. Although most organizations have well organized methods of the flow of material, it is very difficult to find material leakages. They have a direct effect on the bottom line since it is money spend on material that was not taken into consideration during the costing phase. In this post: how to find the leakages and how to reduce their unknown part.