How to Improve Plant Capacity and Minimize Downtime

Workers in plants manufacture and process anything from a box of cereal to a car.

Minimizing downtime and increasing capacity in any plant are crucial steps to maintaining the profitability of a business. Over time, unplanned downtime can grow into a huge problem that creates a lot of loss for your company. Reducing downtime, no matter the cause, is one way to improve your plant capacity. Also, increasing your plant's capacity in other ways can result in more production and lower margins. Each plant has its own circumstances and requirements, so be sure to tailor any strategies to rules and regulations that apply to your plant.

Instructions

1. Research causes of unplanned downtime and reduction in capacity over the course of a year in your plant by reviewing company records or speaking to plant managers. Measure the amount of time or productivity lost and the financial impacts on the company. Downtime or capacity problems can be caused by faulty equipment or poorly managed employee groups, so look for problem areas that may be at fault for a higher percentage of downtime or decreased capacity. Also, look for bottlenecks that could be slowing up production, such as a department where all of your plant's products are held for days unnecessarily.

2. Look for ways to improve capacity by improving machinery, increasing raw material inventories or implementing more efficient material handling protocol. For example, consider installing automated transportation systems for raw materials, such as vacuum systems for bakery ingredients.

3. Repair or maintain any machines that are causing a reduction in capacity or an increase in unplanned downtime. If there isn't one in place, institute a maintenance plan to attempt to prevent future problems. If possible, replace old equipment to improve plant capacity and reduce the risk of breakdowns.

4. Educate your team about downtime and ways to improve plant capacity. Present the information found in your research and discuss what you believe is causing the plant's problems and what the team can do to help correct it. Some examples include using machines properly, setting up equipment more efficiently or maintaining inventory levels to avoid work stoppage.

5. Set goals for reducing downtime and improving capacity each quarter, and ensure that all employees are expected to help meet these goals. Give out weekly or biweekly reports on the employees' progress toward meeting goals. If possible, give reports in real-time through display screens or employee emails to create a sense of urgency about meeting the goals.

6. Celebrate successes after employees meet their goals. If goals aren't met, repeat Steps 1 through 5 and look for new ways to improve capacity and reduce downtime.

Tips & Warnings

• If you can't identify the cause of downtime or capacity problems, consider instituting a program requesting suggestions from employees.

• Making changes to a manufacturing procedure could have an impact on certifications or approvals. Consult your supervisor before making changes to procedures and protocols.

References

• Vorne Visual Displays and Productivity Tools: Reduce Downtime
• Snack Food and Wholesale Bakery: Increase Capacity and Minimize Downtime