Productivity Center
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You may encounter many problems while performing your activities in your business. You don't have to make a new discovery in solving these problems. Just contact us.
Basic Problems Seen in Production Processes
Problems and Solutions in 4 Basic Categories
Person
Constant employee changes can reduce productivity and cause loss of internal experience and knowledge.
We are constantly working overtime
Employees constantly complain
Human error abounds
Absences are high
Education level is very low
Lack of training and development programs to improve employees' skills can reduce productivity in the long run.
There's too much gossip
Increased conflict between co-workers or managers can negatively impact the work environment.
Lack of motivation of employees may reduce production quality and speed.
Wrong hires or inadequate onboarding processes can lead to inefficiency and non-compliance.
Work Accidents and Safety Violations occur
Defects may occur in products as a result of personnel shortage, lack of training or carelessness.
Defects may occur in products as a result of personnel shortage, lack of training or carelessness.
Communication deficiencies may occur between workers and upper management, between departments, or between workers and workers.
Lack of teamwork can make it difficult for business processes to function properly.
Machine
Malfunction and Maintenance Problems Frequent malfunctions may occur due to excessive use of machines, inadequate maintenance or wear.
Production Stoppage Stoppage of production lines due to machine malfunctions or maintenance requirements can lead to loss of time and resources.
Inefficient Production Inadequate operation of machines or low efficiency can negatively affect production processes.
Quality Issues Machine problems can affect product quality. For example, semi-finished products or products do not have the desired properties.
Production Planning Challenges Machinery malfunctions or outages can complicate production planning and impact delivery processes.
Energy Consumption Inefficient or old machines can lead to high energy consumption, which can increase costs.
Personnel Training Inadequate training in the use or maintenance of new machines can lead to errors and problems.
Spare Parts Supply Problems Spare parts supply problems may occur, especially for old or customized machines.
Technological Updates If machines are not technologically up-to-date, this can reduce productivity and cause loss of competitiveness.
Lack of Data Analysis and Prediction A lack of data analysis and predictive models to monitor machine performance and predict maintenance needs can lead to problems.
Material
Material Supply Problems Failure to obtain the necessary materials on time may cause disruptions in production processes.
Insufficient Stock Insufficient material stocks can lead to production line stoppages or delays.
Material Quality Problems Poor quality of materials coming from suppliers may negatively affect product quality.
Material Changes Sudden changes in the properties of materials coming from suppliers can affect production processes.
Cost Increases Sudden increases in material prices can increase production costs.
Supplier Problems Problems may occur due to suppliers' financial problems, delivery difficulties or low reliability.
Material Waste: Material waste may occur due to faulty production or incorrect stock management.
Logistics Problems Problems experienced in the transportation and storage processes of materials can affect the production flow.
Lack of Process Compliance Lack of adequate process control to ensure the conformity of materials to the production process can lead to quality problems.
Search for Alternative Materials If there is difficulty in procuring a particular material, the search for alternative materials can be challenging.
System
Production Planning Challenges Production line overload or inadequate planning can disrupt production processes.
Lack of Efficiency Unoptimized production line or unnecessary complexity of processes can reduce efficiency.
Product Variety Challenges Producing different products on the same production line can complicate production processes.
Product Changes Frequent changes in product design or specifications can disrupt production processes.
Material and Equipment Mismatch Problems Mismatch of materials or equipment to the production line can reduce productivity.
Lack of Process Control Inadequate control of production processes can lead to faulty production or quality problems.
Standby and Idle Capacity Holds or idle capacity on the production line can lead to inefficient use of resources.
Raw Material Supply Problems Raw material supply problems may occur that prevent the regular flow of production processes.
Inadequate Workforce Planning Lack or excess of workers can affect production processes.
Lack of Technological Infrastructure Inadequate or outdated production technologies can negatively affect efficiency and competitiveness.
Inadequate Leadership Productivity losses due to employees' lack of organization in line management and inadequate leadership models.
MUDA - MURI - MURA Losses
We Have Solutions
Above you can see the business problems arising from 4M, which includes all processes. If you are experiencing one or more of these problems and looking for a solution, we can share with you what we know, our experiences and our solution methods.
Solutions in Your Production System
Establishing a Production System that covers all elements of the supply chain in accordance with the vision of your business, in accordance with the corporate culture or the culture desired to be created.