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6 Tips for an effective production


1 - How to correctly manage your spare and ware parts stock.
2- Strong and constant personnel training
3- Periodic preventive maintenance of equipment and machinery
4- Standardization of processing product
5- Implementation and maintenance of quality standards
6- Standardization of production processes

1- How to correctly manage your spare and ware parts stock:

The reasons that justify the existence of inventories in production plants are numerous.
We can however highlight one above all:
The need to cope with the demands of customers while attempting to avoid interruptions in the process of production or provision of services doe to the unexpected damages of equipment and machinery.

Interruptions in the production process can be derived from problems in delivery of raw material, components acquired abroad, or any difficulty in the internal operation of the company. Any of these can cause a stop at any stage of the manufacturing process, if there is no enough stock of raw materials to work with or spare and ware parts to fix a problem in the machinery. To avoid any interruption, the company tends to create a manufacturing stock; these stocks not only accomplish the goal of preventing unscheduled or unwanted stops, but they allow in addition, to cope with unexpected production increases.

You should also be aware that there are products that take up to 6 months to be produced specifically with the requirements of the customers.

Spare or wear parts:

Spare or wear parts are just that, parts that are consumed or worn during the process of production, as sanding belts, thermal blankets, additives and many others. Managing a stock of these products is of great importance and is relatively easy to calculate.

It is important to have a consumption analysis by different periods of the operational year; with this information you can organize annual or semi-annual purchases and thus reduce import costs, packaging and most important to negotiate low prices with suppliers, making a consolidation of centralized purchasing, and achieving more benefits for each company.

The important thing to take into account at when having a stock is that many of these products have a correct or specific storage, you can for example; shorten the life of a grinding belt by not keeping them hung in spaces with a humidity level base (depending on each producer).

It is also important to manage a rotating stock (of consumption) as well as a fixed stock (for emergencies) to avoid unplanned shutdowns of lines.

Remember that having annual contracts with suppliers and a good periodic consumption analysis, you can reduce the level of stock in warehouses.

To summarize the important points are:

1. Creation of a consumption analysis by product by periods (monthly, quarterly, half-yearly and yearly).
2. Annual contracts with producers and suppliers.
3. Group orders (cluster purchases), purchases for all production plants and not one by one, this reduces costs by negotiating with suppliers, import values, packaging and others.
4. Proper storage to avoid shortening the life of materials.

Spare parts:

These are parts that have a longer lifetime (under the correct parameters), but that in turn are vital for the proper maintenance and operation of the production lines.

Generally, machinery suppliers always deliver a list of spare parts, when they are acquired; these lists are of utmost importance to know what the most common and important parts within each production line are.

The best way to build your spare part stock:

1. Have a list of spare parts for each machine (list delivered by the supplier)
2. Keep a history of repairs of each machine (estimating life of parts repaired)
3. Periodic technical visits for assessment and prevention of damage.
4. Creation of a specific check list to each production line per shift, preventing any damages and generating status reports, (this prevents damage from spreading to other parts of the line)

In short, stock management is crucial to the existence and maintenance both preventive and corrective of production plants.

Inserco Industry service is proud to provide for over 30 years a Just-On-Time service for all spare and ware parts requested urgently.

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