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
Dave Luckner presenting Protected Flow Manufacturing today at VMCAUG in Ontario, Canada. Results that allow manufacturers to deliver on time, in less time, everytime – and it proves it’s work – put it to the test, it’s ready for your toughest challenge! What’s Next: Read Cindy Jutras’ report of how LillyWorks is challenging the long held… READ MORE
These articles are portions of a lecture presented to APICS by our friend Gene Caiola. In our last segment titled “Finite Scheduling – Not So Easy To Be Successful” we left off after realizing that Finite Scheduling was a bit more work than it was worth… Protected Flow Manufacturing – a Revolutionary New Approach The… READ MORE
Come by and visit Dave Luckner and Protected Flow Manufacturing today at EASTEC in Springfield, MA – we’re in booth #5828
This is the second of four blogs on Production Scheduling and the 3 Shop Floor Fundamentals. In the first, I described how I met a VP of Operations who, in spite of having an ERP with scheduling functionality in it, is struggling to answer these questions, which I call the 3 Shop Floor Fundamentals: In this… READ MORE
Manufacturing and thoroughbred race horses – what do they have in common? During a tour of the Kentucky Derby Museum a couple of years ago, I learned that many of the fastest thoroughbred race horses have what are considered to be abnormally large hearts. Secretariat, the famous 1973 Triple Crown winner, who won the last… READ MORE