Time-poor managers can't improve systems, says research

By Rick Pendrous

- Published: 29 August, 2008

Page 23

Daily 'fire fighting' problems are preventing many firms from having the time to become more efficient, reduce waste and improve their profitability, according to new research funded by the Department for Environment, Food and Rural Affairs.

The research, which is about to publish its results, concluded that while there were a number of tools and approaches that could be used to improve competitiveness - such as change management, lean manufacturing, sustainable manufacturing concepts and using performance measures to aid productivity improvement - the biggest obstacle was restrictions on management capability.

For many managers, the workload required in responding to changing customer demand did not allow them time for a detailed analysis to develop a true understanding of their plant's profitability, according to research associate Dr Pius Coxwell Achanga, who worked closely with lecturer Tom Ridgman from the Institute for Manufacturing at the University of Cambridge and researchers from the University of Lincoln in this project.

Part of the project involved a series of training workshops, undertaken with Premier Foods, Bakkavör and Produce World. In the workshops a manufacturing factory simulation was used to illustrate the advantages of 'just-in-time' production. As part of the simulation, teams had to deliver three different products through a three-stage production process.

The use of lean tools such as: SMED -'single minute exchange of dies' (designed to speed production changeover between products); 'takt time' (the maximum time allowed to produce a product to meet demand); and ¬ 5s (a methodology for improving efficiency by eliminating waste), were demonstrated.

The researchers attempted to show that while demand can appear random, if analysed, patterns can be identified and the odds of abnormal demand calculated and strategies taken to minimise waste.

All systems go for improvement

A masterclass designed to help manufacturers adopt 'best practice' in their operations is being staged this month.

The one-day seminar, chaired by lean manufacturing and total productive maintenance (TPM) guru Peter Willmott, will take place in Oxford on September 17.

In addition to a keynote presentation by Dr Nick Rich from Cardiff University, Premier Foods, Constellation Brands and Carbon Trust will also be presenting.

The event is sponsored by software specialist Idhammar Systems, which provides products designed to help firms improve their overall equipment effectiveness (OEE) and computerised maintenance management systems (CMMS). Idhammar has worked with Burton's Foods and Tryton Foods.

For more details call Rebecca James at Idhammar on 0117 920 9400