Excess inventory eating into margins, parts shortages reducing customer-satisfaction levels, resulting in fewer customers and lost revenues are some of the challenges creating manufacturing inefficiency.
Manufacturers committed to on-time delivery, optimizing inventory levels, and reduction of expediting-related expenses are proactively seeking solutions to these challenges. Adding to the challenge is the fact that customers expect higher levels of service, better pricing, reduced lead times, and access to ever-increasing finished-good SKUs.
Manufacturing has become more competitive than ever. In today’s competitive environment, manufacturers are seeking ways to maintain profitability by eliminating waste. This waste is usually a result of inefficiencies that exist on the shop floor, in labor, and with inventory expense. There is often a misalignment of production lines and non-standardized operating procedures.
The mandate for greater efficiency is leading companies to embrace Lean Manufacturing as their preferred approach to eliminating waste and streamlining processes for cost effectiveness.
Ultriva addresses the challenges of production inefficiency with Ultriva Lean Factory Management (LFM), a cloud-based application that optimizes production job sequencing and supply chain material replenishment. LFM can work in conjunction with other Ultriva LeanSuite applications or function as an independent application.
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Delivering a clear view of weekly or monthly production, including identification of potential over/under capacity situations, LFM provides manufacturing operations with the tools needed to align production resources with customer demand, improve build plans, shorten lead times, and reduce inventory.
LFM informs a manufacturer whether a particular cell is over capacity or underutilized on a day-by-day basis. As a result, supervisors dynamically adjust schedules to meet “customer want” dates.
Supervisors use LFM to easily change production sequences that minimize set-up and optimize production. A supervisor monitors multiple cell production schedules from a central location and manages schedules based upon resource availability or customer demands.
LFM sets up multiple materials flow loops using work centers for consuming lines (Final Assembly) to producing lines (Sub Assembly) and storage locations (supermarkets).
Moving production resources away from inaccurate forecasts, LFM enables manufacturers to:
Factory operators using LFM enjoy great flexibility. Operators’ jobs can be grouped by:
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