What is Waste in Manufacturing? In Lean Manufacturing, waste means any activity that consumes resources but does not add value from the customer’s perspective. A process can look busy and still contain significant waste The 8 Wastes Simple Example An operator produces a component in 30 seconds, but spends another 10 seconds walking to collect […]
The customer called three times. Same complaint. “The product is good, but it is difficult to use.” Quality checked the product. It passed every test. Production checked the process. Everything was within standard. Engineering checked the drawings. No problem there either. So the team visited the customer. They watched how the product was actually being
What is a Manufacturing KPI? A Manufacturing KPI (Key Performance Indicator) is a measurable value used to understand how effectively a manufacturing process is performing. KPIs turn production performance into data that can be monitored and improved. In simple terms Instead of saying: “Production seems slow.” A KPI helps quantify it: Output = 8,500 units
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“Don’t change anything.” That was the instruction from the Production Manager. The line had been running for years. Same machines. Same layout. Same work method. Same problems. One young engineer noticed that operators were making the same small adjustment almost every hour. She asked why. An operator replied: “Because the machine doesn’t work properly without
What is Performance Rate? Performance Rate measures how fast a machine or production process operates compared with its ideal or planned production speed while it is running. It helps answer: “When the machine is running, is it producing as fast as it should?” In simple terms A machine may be available for production but still
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“Why are we producing this?” Nobody answered. The Production Manager looked at the planning sheet. The order was approved. The material was available. The machine was ready. So production continued. Two days later, the finished products were sitting in the warehouse. Nobody was asking for them. The Planning Manager checked the customer order. The customer
What is Quality Rate? Quality Rate measures the proportion of produced units that meet the required quality standards compared with the total units produced. It helps answer: “How much of what we produced was good without being rejected?” In simple terms If a process produces 1,000 units and 30 units are defective: Good units =
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“We don’t have it.” The Plant Head thought he had heard wrong. “What do you mean?” “One component is out of stock.” The entire production line was ready. Operators were waiting. Machines were ready. Orders had to be shipped. The missing component? It cost less than ₹20. “Check the warehouse.” Nothing. “Check incoming material.” Nothing.
What is Voice of the Customer? Voice of the Customer (VOC) is the process of collecting and understanding customer needs, expectations, requirements, and feedback. It helps manufacturers understand what customers actually value not just what the company assumes they value. In simple terms A customer may say: “I need faster delivery.” But the real requirement
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What is PMTS? PMTS stands for Predetermined Motion Time System. It is a work measurement technique used to determine the time required to perform a task by analyzing the basic human motions involved, rather than measuring the entire task repeatedly with a stopwatch. In simple terms Instead of asking: “How long did this operator take?”
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