\n
I<\/span>mproving productivity depends on a combination of efficient employees, <\/span>equipment and processes. <\/span>Driving improvement in all these areas involves examining the current practices in place and making adjustments to systems, <\/span>employee training, <\/span>technology, <\/span>equipment and tools. <\/span>From small tweaks in communication processes to large technology improvements, <\/span>companies are using many techniques to boost productivity.<\/span><\/p>\n From small tweaks in communication processes to large technology improvements, companies are using many techniques to boost productivity.<\/p><\/blockquote>\n Tecsew Ltd. <\/span>in Gosport, <\/span>Hampshire, <\/span>U.<\/span>K., <\/span>includes a video on its website that explains one of the primary ways it manages production efficiently\u2014<\/span>with materials requirements planning (MRP) software. Before 2006, \u201cproduction was managed using a series of Excel spreadsheets,\u201d the video\u2019s narrator says. \u201cThe company realized that, if it were to expand and move away from the inherent problems that a fragmented approach to production management causes, they would need to upgrade to a more integrated solution.\u201d<\/p>\n<\/div>\n John Bland, <\/span>managing director of Tecsew, <\/span>which designs and manufactures marine covers and upholstery, <\/span>lauds the MRP software of U.<\/span>K.-<\/span>based 123 Insight Ltd. \u201c<\/span>Quotes, <\/span>invoices, <\/span>orders, <\/span>etc., <\/span>can be emailed automatically, <\/span>as well as dialing out from the database to a client or supplier,\u201d <\/span>he says. \u201c<\/span>Our quotes include a photo of the person who has prepared the quote, <\/span>which gives it a human touch.\u201d<\/span><\/p>\n He adds that 123 generates reports and that, <\/span>although it is \u201c<\/span>not cheap and is laborious to set up,\u201d <\/span>the benefits are well worth the investment of money and time.<\/span><\/p>\n In addition to automation equipment and software, <\/span>Tecsew follows a range of productivity principles, <\/span>including lean and just–<\/span>in–<\/span>time manufacturing, <\/span>key performance indicators, <\/span>workforce incentives and employee empowerment. \u201c<\/span>I\u2019<\/span>m always looking to improve, <\/span>to get an edge, <\/span>so always keep an eye out for anything that can add value,\u201d <\/span>Bland says. \u201c<\/span>Profitability and market share will suffer as a consequence of not moving forward.<\/span><\/p>\n \u201cLook at what others do,\u201d <\/span>he suggests. \u201c<\/span>If you have an idea and it\u2019<\/span>s not being done, <\/span>research, <\/span>explore and implement. <\/span>Have an open mind, <\/span>and always be prepared to try out an idea. <\/span>Embrace new technology and reap the rewards.\u201d<\/span><\/p>\n A frame fabricator at Tecsew assembles a frame bent with a CNC ring roller (<\/span>not shown). <\/span>The programs for bending the frames are taken from models prepared in Rhinoceros 3–<\/span>D CAD software. <\/span>Photo: <\/span>Tecsew Limited.<\/span><\/p>\n Tecsew uses a Tauring CNC ring roller to bend frames, <\/span>a Prodim Proliner for measuring and making templates, <\/span>a Logitech digitizing board for inputting templates and a Blackman & <\/span>White Genesis conveyor cutter with a laser–<\/span>guided fabric feeder.<\/span><\/p>\n \u201c[<\/span>The latter] <\/span>replaced a flatbed model requiring a larger floor space and was restricted to the size of the table in terms of the length of fabric that could be cut,\u201d <\/span>Bland says. \u201c<\/span>With the conveyor, <\/span>we can cut a whole roll of fabric.\u201d<\/span><\/p>\n The company also has computer–<\/span>aided manufacturing software that works hand–<\/span>in–<\/span>hand with the roller and cutter and three computer–<\/span>aided design (<\/span>CAD) <\/span>programs. <\/span>Bland cites 3–<\/span>D CAD as having the biggest impact on Tecsew\u2019<\/span>s productivity.<\/span><\/p>\n Ohio Awning & <\/span>Manufacturing Co. <\/span>also uses 3–<\/span>D CAD software.\u00a0<\/span>\u201cThe 3–<\/span>D helps create very nice drawings for customer approvals and shop drawings for construction, <\/span>and being able to convey what we are planning to do in a much more clean and professional way than we have in the past,\u201d <\/span>says William Morse, <\/span>vice president. \u201c<\/span>It helped us from the outset from a customer perspective and in doing things the right way.\u201d<\/span><\/p>\n You can store the file for easy recall when it is necessary to make the same product years later, without the need to rummage through stacks of paper patterns.<\/p>\n \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 <\/span>~ Truy Pham, Autometrix<\/span><\/p><\/blockquote>\n However, <\/span>the Cleveland–<\/span>based company has not found the right software for overall manufacturing management, <\/span>so it has developed its own \u201c<\/span>stopgap of using an integrated database that ties together different elements of the company,\u201d <\/span>Morse says.<\/span>He offers two actions that have made a major impact on productivity: (<\/span>1) <\/span>acquisition of a digital cutting machine within the last couple of years and (<\/span>2)\u00a0<\/span>relocation from the four–<\/span>story building it occupied for 85 years to a one–<\/span>story building, <\/span>which provided an opportunity to design with workflow in mind.<\/span><\/p>\n \u201cWe also have done a lot of little things, <\/span>a tweak here or there, <\/span>such as adding attachments to sewing machines to automate some processes, <\/span>like easily creating a fold,\u201d <\/span>Morse says. \u201c<\/span>It\u2019<\/span>s a simple thing that has made a big impact on the amount of time people spend doing things.\u201d<\/span><\/p>\n Autometrix Precision Cutting Solutions has developed a series of automated cutting machines to fit any size company. <\/span>Its newest product, <\/span>CADShot Mobile<\/a>, <\/span>won an IFAI Expo 2016 Show Stopper Award. <\/span>The software turns existing patterns into digital pattern files.<\/span><\/p>\n \u201cIt saves an immense amount of time over re–<\/span>creating the pattern in CAD,\u201d <\/span>says Truy Pham, <\/span>Autometrix national sales manager. <\/span>\u201c<\/span>You can store the file for easy recall when it is necessary to make the same product years later, <\/span>without the need to rummage through stacks of paper patterns.<\/span><\/p>\n \u201cAccessibility to the technology is how our company and the industry will grow,\u201d <\/span>he continues. \u201c<\/span>Currently, <\/span>our best–<\/span>selling products are static tables<\/a>. <\/span>Besides us being able to customize the table to any length and width to accommodate fabric–<\/span>roll specifications, <\/span>our Radium and Argon models have options and features to make them suitable for many types of industrial fabrics manufacturers.\u201d<\/span><\/p>\n Headquartered in Grass Valley, <\/span>Calif., <\/span>Autometrix has clients in Europe, <\/span>Asia and the Americas. \u201c<\/span>Our job is to observe the movement of people, <\/span>fabric and paperwork in a shop. <\/span>We then present a solution on how implementing the right software<\/a>, <\/span>cutting system and material–<\/span>handling devices will promote a more productive and eficient organization. <\/span>A lot of times, <\/span>we find that the right investment is not always the highest cost,\u201d <\/span>Pham says. \u201c<\/span>Our goal is to give clients a system where CAD experience is not necessary. <\/span>We want to make it simple for them to generate patterns and keep the machine cutting.\u201d<\/span><\/p>\n Our goal is to give clients a system where CAD experience is not necessary. We want to make it simple for them to generate patterns and keep the machine cutting.<\/p>\n ~ Truy Pham, Autometrix<\/p>\n<\/blockquote>\n The Dize Co.,<\/span> an awnings fabricator in Winston Salem,<\/span> N.<\/span>C.,<\/span> also uses CAD software.<\/span> But president\/<\/span>CEO Fred Burke has no plans to purchase automation equipment in the next 24 months, <\/span>in part because his focus is on investing in employees.<\/span><\/p>\n \u201cAlso, <\/span>we have had to invest in new vehicles for new installation crews,\u201d <\/span>he says. \u201c<\/span>Back orders were a choking point. <\/span>New technology won\u2019<\/span>t help me until I can get awnings installed on buildings.\u201d<\/span><\/p>\n Patrick Hickey, <\/span>president of Minnesota Knitting Mills in St. <\/span>Paul, <\/span>says his company has continued to update equipment and touched on a wide range of productivity–<\/span>boosting practices\u2014<\/span>taking tenets from multiple concepts and \u201c<\/span>applying them to a given situation or process flow,\u201d <\/span>he says. \u201c<\/span>While not fully adopting nor acquiring specific programs such as Six Sigma, <\/span>we have reviewed them all and \u2018<\/span>nested\u2019 <\/span>them in a fashion that makes sense for what we are trying to accomplish.\u201d<\/span><\/p>\n \u201cFinding quality people with good leadership skills and placing them in key positions can have the greatest impact on productivity,\u201d <\/span>Hickey asserts.<\/span><\/p>\n Dize takes a similar approach. \u201c<\/span>I went out to get the right people and was willing to pay for that,\u201d <\/span>Burke says, <\/span>noting that he \u201c<\/span>upgraded job profiles to attract the right people.\u201d<\/span><\/p>\n This past spring, <\/span>the company paid employees a piece rate in addition to a flat hourly rate as a productivity incentive. \u201c<\/span>It\u2019<\/span>s been very well accepted and makes us more eficient,\u201d <\/span>Burke says.<\/span><\/p>\n Ohio Awning also uses monetary rewards to encourage employees to increase productivity, <\/span>offering bonuses tied to a point system. \u201c<\/span>Where we have been very successful with it is with installers,\u201d <\/span>Morse says. \u201c<\/span>We have incentivized them to get so much work done per day.\u201d<\/span><\/p>\n Most important, <\/span>communication is essential to maintaining a productive workforce.<\/span><\/p>\n \u201cAutometrix equipment is owned by two–<\/span>employee shops and Fortune 50 companies,\u201d <\/span>Pham says. \u201c<\/span>The commonality I\u2019<\/span>ve noticed is that employees of our clients have an avenue to have their voice heard to improve everything from working conditions to manufacturing workflow.\u201d<\/span><\/p>\n Ohio Awning seeks input from employees by simply asking them how they would change the way things are done to make processes more eficient. \u201c<\/span>People speak up and let you know, <\/span>because it impacts them as well,\u201d <\/span>Morse says. \u201c<\/span>There are quite a few things we have adopted based on input from people in the sewing room and welding shop. <\/span>In sewing is where a lot of things have had the biggest impact in the overall product.\u201d<\/span><\/p>\nThe right investment<\/h3>\n
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<\/a>People power<\/h3>\n
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