Despite being an established, leading and very competitively placed sand casting company, Badger Alloys had the potential to improve both its process and employee efficiency.In order to improve efficiency on these two fronts, Badger Alloys had two significant problems they had to overcome.
These were as follows.
1. Reporting on jobs carried out in the company’s critical core/clean room
2. Having a bi-lingual workforce, the lack of illustrative ‘How to’ guides/documentation that would help to clearly understand and execute assigned processes
Despite being a leading market player, core/clean room scheduling, labor costing, labor scheduling and critical performance metric reporting was an ad-hoc, time consuming and inconsistent process. In an industry where process instructions included very specific instructions such as where to cut off risers to prevent overgrinding, what parts to use, what patterns to use and how optimal a particular welding should be, it was clear that instructions in
the written form weren’t being conformed to, at least not at the optimal levels desired by BadgerAlloys management.
Another critical issue impacting both production technicians and process productivity was the dependence on a dated scheduling and reporting system. Technicians contributed on any number of on-going production jobs without recording their activities and time. This variability resulted in a lack of data capture which limited the ability to capture labor job costing, a metric that would otherwise produce actionable management intelligence.
This lack of purposeful scheduling meant that manufacturing resources were not allocated with the appropriate priority. Instead they spread their time evenly across all projects without tactical purpose driven by due dates and profitability. Not only was manufacturing not strictly adhering to data driven scheduling, but their own input of data was restricted to a single shared central kiosk which resulted in critical time lost and an additional lag in time for otherwise actionable data.