Shop floor chaos can feel inevitable when priorities change by the hour and everyone is chasing the latest crisis. Why does it keep happening, and can you actually stop it? Yes – when you give people clear, real-time priorities they can trust. At LillyWorks, we see the same pattern in discrete manufacturers of all sizes.… READ MORE
The Misunderstanding About Throughput Most manufacturers equate an increase in throughput with running machines faster or adding capacity. But that approach often leads to more work-in-process (WIP), more chaos, and the same output at the end of the day. The truth is, throughput in manufacturing isn’t just about doing more – it’s about keeping flow… READ MORE
Manufacturers today are often inundated with dashboards displaying a dizzying array of key performance metrics for manufacturing. From overall equipment effectiveness (OEE) and yield rates to first-pass quality and inventory turnover, the sheer volume of data can be overwhelming. But amidst all the numbers and charts, which key performance metrics for manufacturing truly signal the… READ MORE
Every manufacturer knows they need to calculate process capacity to understand their production limits – how many units can a machine produce per hour, how many orders can a work center handle in a day. These calculations provide a theoretical ceiling, a benchmark against which performance is often measured. But knowing your theoretical maximum is… READ MORE
Today’s manufacturers are awash in shop floor data. Sensors, systems, and reports generate more information than ever—machine performance metrics, real-time inventory levels, and employee productivity tracking. The promise is that this wealth of data will deliver greater visibility and more effective shop floor management. But is it really improving decision-making and outcomes? Or are we… READ MORE
Many manufacturers invest in sophisticated advanced planning and scheduling (APS) systems, hoping to create the perfect production blueprint – a meticulously crafted sequence of operations designed to optimize resources and ensure timely completion. The promise of these systems lies in their ability to foresee potential bottlenecks and proactively allocate capacity. But what happens when the… READ MORE
In the world of manufacturing, efficiency is paramount. One of the biggest hindrances to a smooth manufacturing process is what’s known as a ‘bottleneck’. This term refers to the point in the production line where work accumulates faster than it can be processed. Fortunately, scheduling software has emerged as a powerful tool to address and… READ MORE
HAMPTON, NH — July 20, 2017 — *(GLOBE NEWSWIRE) — “Because consumers now demand ‘instant gratification’ and have mind-boggling amounts of choice, manufacturing today is driven by demand. To be successful, a manufacturer must have the right products and materials – *and enough supply on hand – to fulfill customer expectations,” says Dick Lilly, founder and… READ MORE
Mark is killin’ it presenting Protected Flow Manufacturing at IMTS in Chicago!
Time Buffers Account for Variability As discussed in the previous article (1 of 5), an everyday task such as driving is a relatable activity that can help us think through the issue of production scheduling. The goal of our thought exercise is to apply the concepts to our manufacturing scheduling practices and improve our operations. To… READ MORE
The Difficulties of Scheduling Around the Assumption that Everyone, and Everything Will Work Exactly as Planned In the previous article (2 of 5), we talked about planning our daily drive. We introduced the concept of using a time buffer to account for the unexpected. We also talked about the threat of incurring penalties in case our… READ MORE
— If we haven’t accounted for variability, our plan can go awry — Who doesn’t rely on planning experts nowadays? There are financial planners, diet and nutrition planners, life planners, and on and on it goes. It seems as if we can’t manage our complicated, time-stressed and hectic lives on our own. Perhaps we’ve been humbled… READ MORE