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Problem

  • Manufacturing production schedules and run lists were being prepared manually by one person with deep understanding of the production processes.

Issues

  • The manufacturing knowledge was tied up with one person, creating a potentially dangerous knowledge dependency.
  • The manual process took a minimum of 8 hours each week.

Solution

  • Create a custom database application
  • This application used a very simple user interface but created very specific production schedules and run sheets.
  • The run sheets were distributed to plant managers to communicate production requirements.

Results

  • Production planning time reduced to 30 minutes (from 8 hours)
  • Better utilization of production resources
  • Decrease in production waste due to improved communication
Randy BassettCase 1: Production Planning