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Question submitted on 15th Nov 2001
I am in a quandary. My current weekly output is between 150 and 200 items (both frames & doors) using conventional machinery. I supply exclusively for the trade. I am planning to increase my output to 350 items per week. Because my strength is selling I am confident that I can achieve the extra volumes. I have seen the representatives from a number of machinery companies who all extol the benefits of their products. What process should my foreman & I follow to be sure I get the best balance of machines and men?
David Amos answered on 30th Oct 2001
An obvious point but you do need machinery to make windows and doors. What you also need is a combination of machinery and people that will produce 350 items per week, not 1350 items per week. A plan you should follow is set out below:

  • Determine the capacity of every one of your main processes as you are set up NOW. Use a simple process sheet.
  • Examine your processes and layouts to see where your bottleneck is and what you can do to improve that bottleneck by spending as little money as possible. See my think piece Grey Matter Before Greenbacks.
  • Look at purchasing machinery to improve the bottleneck process only.
  • Go back through the process; bottleneck by bottleneck until you have 350 items per week.
  • Then determine the benchmarks for your production operations and measure how you compare. Look at our website and access Manufacturing Norms where you can find guidance on how to obtain industry benchmarks.
  • Consider joining our best practice club, details via our website.
  • Give me a call so we can have a deeper discussion.

Incidentally we have a selection of forms and instructions you can use to carry out the process described above.


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