Your plant is falling behind
Safety, quality and efficiency, looked at together.
"How do I turn around a plant that is underperforming."
A plant that is behind is usually behind on several things at once, and each function is solving its own version of the problem. Safety is a safety project, quality is a quality project, and the schedule is somebody else's.
Looked at together, most of it is one problem. Fix the one or two things actually holding the floor back and a surprising amount of the rest quiets down without a project of its own.
25 years of this at Georgia Pacific and Koch Industries, across pulp and paper plants, with ERP improvement and lean manufacturing running through it.
Questions about this one
- Where does a turnaround start?
- On the floor, before any meeting. Two days of watching the operation says more than two months of reports.
- How much of this is people rather than process?
- Most of it, in the end. A process nobody on the floor believes in does not survive the first bad week.
The other five reasons people call
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The seat is empty
Your plant manager just left
The seat is filled while you find the right permanent person.
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Orders are late
You are missing what you promised customers
On-time delivery is the number your customers judge you on.
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Cash is stuck in stock
Too much cash tied up in inventory
Cash sitting in parts nobody needs this quarter.
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The schedule slips
Your schedule keeps slipping
A schedule that looks right on Monday and is gone by Wednesday.
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The team will not move
Your team will not execute
Decisions get made where the work is, or they do not get made.
Let's talk about what is going wrong.
A few sentences is enough. What is late, what is stuck, or which seat is empty.