In manufacturing, running your machines within the given shift time is essential. To maximize uptime and profit margins, you'll want to avoid unnecessary late starts and early stops of your equipment.
With Amper, you can measure these late starts and early stops to see, on average, how much time you are losing each week, month and year. We call these metrics Time to First Part (TTFP) and Time to Last Part (TTLP). We recommend these projects to our customers when they first get started with Amper as the solutions are typically easy to implement and highly impactful.
- Collect and Analyze Data:
- Calculate Opportunity Cost:
- Determine Root Cause: Typically, we see these 3 root causes for a late starts and early stops.
- Implement a Solution:
-Work with your Customer Success Manager to determine, on average, when you started running your production in a given day. At what time did the actual shift start? At what time did your production start? The difference between the two will give your TTFP - or late start.
-Then, look on average, at when you stopped running your production in a given day. At what time did the actual shift end? At what time did your production stop? The difference between the two will give your TTLP - or early stop.
-Look at this data for over a month then extrapolate it out to see how many hours you're loosing/year and how much it costs you using your hourly cost of production. Sometimes you can isolate certain shifts or machine groups that are providing the biggest impact.
Meetings at the start/end of the day
-Possible solution: Push meetings to later in the day when the machines are up and running. Additionally, you can have multiple meetings with smaller groups of direct labor staff at a time, so someone can backfill the machines. You can also have meetings before the available shift time.
-Possible solution : Overlap shifts or have employees stay late to run the machines through the available time. You could have 1st shift stay late to clean while 2nd shift starts production or have the last shift stay late to clean after the machines should have been turned off. Calculate how much it costs you to do that, and see if it outweighs what you're loosing.
Long Machine Warm Up Time
-Possible solution: Bring someone in 1-hour early in the mornings to warm up machines. The cost for the extra hour of labor may be worth the money you're losing not running the machines.
-Set up an internal project team.
-Determine which solution is best for your business and implement it.
-Monitor your TTFP/TTLP with our Amper reports. Talk to your CSM if you would like these emailed to you daily/weekly. Hold your team accountable to the improvement.
**Always check utilization after making the change to see if overall machine utilization goes up in the given available timeframe.