SPM or Special Purpose Machines are not readily available in market and have to be tailor made to suit specific requirements of the customers. These are also known as bespoke machines. These Machines will minimise human errors and gives higher levels of quality and accuracy
What is lean manufacturing technique?
Lean is a methodology to reduce waste in a manufacturing system without sacrificing productivity. Through lean manufacturing management, what adds value becomes clear by removing or reducing everything that doesn’t add value.
Advantage of SPM leading to lean manufacturing techniques.
Time of process.
Time is an important asset and wasting time is therefore wasting money. Reducing the time taken to finish a project is going to create value by adding efficiencies. In conventional machines time needed to finish the project is more since it’s designed to perform only specific operations. But InSPM’smultiple operations can be configured in the single machine which drastically reduces the process time.
Cost reduction
Cost of production is reduced when a company identifies and eliminates non value added activities. Overproduction also adds to storage and warehousing costs. Understanding the triple constraint is the first step to understanding cost management. SPM’s or Special Purpose Machines offer immense scope for high volume production at low investment and at low cost of production when compared to conventional machines. Lean manufacturing can efficiently minimize waste within a production facility.
Quality improvement:
To stay competitive, companies can’t be complacent, but must meet customers’ demands. Therefore, processes must be designed to meet their expectations and requirements. Adopting to SPM with full implementation of Kaizen’s & TPM’s can provide total superior qualitative products at optimum costs.
Standard operating procedure
A standard operating procedure (SOP) which is set up by a company in its manufacturing process for step-by-step instructions compiled to carry out complex routine processes. SPM’s are customised as per the manufacturer’s requirements hence contributes in better SOP management to meet end customer demands.
Kaizen and Kanban with SPM and lean manufacturing
Kaizen and Kanban are terms that are rooted in Japanese business and manufacturing, as it developed in the last half of the 20th century.
Kaizen (Continuous Improvement) is a strategy where employees at all levels of a company work together proactively to achieve regular, incremental improvements to the manufacturing process. In a sense, it combines the collective talents within a company to create a powerful engine for improvement. SPMs are designed to support lean manufacturing and the concept of kaizen for continuous improvement in manufacturing making it lean.
Kanban in manufacturing is an inventory organization structure that uses visual cues to move inventory though various stages of the manufacturing process. It is a tool for lean manufacturing that aims to prevent inventory pileup by initiating production only to restock empty reserves. Special purpose machines are designed to function as per the customised requirements and do not require to over produce the stock.
Implementation of TPM’s
Idle and malfunctioning equipment is a significant source of waste for many businesses. Ineffective maintenance causes equipment to break down, resulting in unproductive periods of downtime.
TPM helps to reduce equipment breakdowns through its Eight Pillars:
- Autonomous Maintenance
- Process & Machine Improvement
- Preventive Maintenance
- Early Management of New Equipment
- Process Quality Management
- Administrative Work
- Education & Training
- Safety & Sustained Success
Operators perform daily maintenance on the equipment they work with and report problems to the maintenance department. The maintenance department, in turn, addresses problems before they cause equipment to break down. When the equipment does break down or produce defective products, the cause is eliminated by updating preventive maintenance programs, investing in new equipment, and by providing additional training as needed.
By Learning and Adapting Above 8 pillars, we can achieve the three goals of TPM,
- Zero unplanned downtime
- Zero product defects
- Zero accidents
No matter which lean manufacturing tool is used (5S, Kaizen, or TPM) businesses will increase profit by improving flow and reducing waste
Conclusion
Special purpose machines and lean manufacturing should go hand in hand and contribute to in providing superior quality products @ affordable cost to the customers. We, M/s.Mikro Innotech Pvt. Ltd. provides turnkey solutions from concept to commissioningto Auto/Aerospace/Pharma/FMCG/ R&D industries by providing our state of the art technology products to suit the customer requirements. Our innovative concepts and high quality machines are proudly owned by reputed industries in various sectors highlighted above. Contact us for all your manufacturing needs and turn your business profitable by practicing lean manufacturing. We are eager to join our hands in your success! Hoping for Good & Long-Term Association
