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Original Date: 06/02/1997
Revision Date: 01/18/2007
Information : Production Monitoring
Sharretts established a Production Monitoring system to track the production of its three zinc-plating lines by week and shift. These plating lines are the largest cost drain to the company, considering they require 75% of Sharretts’ resources.
In September 1996, Sharretts began monitoring the cycle times of the zinc-plating lines. To document the processes, flow charts were developed. Since October 1996, Sharretts has posted graphs of the cycle times and performance parameters, and recorded the results (Figure 2-1) in a process information book. Chemical adjustments to a process are also identified through the monitoring system. Maintenance and frequency of breakdown tracking by the Production Monitoring system has led to scheduled preventive maintenance. Sharretts holds weekly meetings to address production and quality problems; maintenance issues; production forecasts and improvements; environmental issues; or to have open-format discussions. Action items are identified at the meetings and assigned to personnel with due dates.
Since starting its Production Monitoring system, Sharretts has documented significant increases in the productivity of its line processes. Previously, one of the zinc-plating lines produced 45,000 pounds in five days. Production is now over 120,000 pounds in five days and productivity has increased by 300%. Significant reductions in the operating costs of the zinc lines have also been realized.
Figure 2-1. First Quarter 1997 Performance
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