Shopfloor management is already bringing us results

Shopfloor management is already bringing us results

We only introduced this popular, and most importantly, extremely effective, method of production management at TMETAL in September 2024. However, we already know that the implementation of shopfloor management was a step in the right direction.

The (European) industry is going through an extremely challenging time. A lot has changed in recent years. If you want to continue to beat the competition, you have to continuously optimize processes, innovate and constantly look ahead.

If you only find out about the error a week later, it's too late.

If you don't listen to employees in lower positions, it's wrong.

When the right hand doesn't know what the left hand is doing, it's trouble.

We at TMETAL are fully aware of all this, which is why in September 2024 we began implementing shopfloor management, which brings better communication, awareness at all levels of the company, the ability to immediately solve problems, and many other positives.

Regular meetings improve awareness and problem-solving skills

The basic mechanism is not exactly a science. It is enough for the right people to gather for a few minutes during the day in structured meetings. Each level (tier) will share the necessary information at its own meeting and evaluate key indicators based on the (current) goals of the company.

When a problem arises, solutions are sought immediately. This usually nips problems in the bud. In many cases, regular communication with the team can even pave the way for preventive measures that effectively avoid potential risks.

And if you can't resolve the situation at a specific meeting, problems and information (not just operational ones) escalate from lower levels upwards. The biggest challenges then "bubble" up to the top management.

Thanks to shopfloor management, the entire company pulls together

At TMETAL, the lowest-level meeting always starts 5 minutes before the shift, so at 5:55 a.m. and 13:55 p.m. There, the foreman meets with the production workers to exchange basic information and clarify the direction of continuous improvement.

The meeting always lasts only about 5 minutes and has fixed rules and structure to ensure that time is used as efficiently as possible.

The meeting, which is an order of magnitude higher, starts at 8:00 and concerns production managers, designers, purchasing representatives, sales representatives, and last but not least, technical control.

Then there is only a meeting of the top management.

Symestic states in a technical article on its website that Successful implementation of shopfloor management typically brings businesses:

• productivity increase by 20 to 30%,
• reducing quality problems by 15 to 25%,
• shortening the response time to problems by 40 to 60%,
• significantly higher employee satisfaction.

So let's see what the implementation of shopfloor management will bring to us at TMETAL. However, the first results are very positive. We have already caught problems several times in the beginning, which could have been solved almost immediately without any major costs and losses. At the same time, we have significantly reduced ineffective email communication, phone calls, etc. Within 15 minutes, the most important production and organizational matters are discussed and everyone is clear.