MANAGEMENT of MANUFACTURING SYSTEM — KMBN OM405
Table of Contents
Overview — What is Manufacturing System Management?
Manufacturing system management is the art and science of planning, controlling and improving the whole production chain — from raw-material intake and process design to quality checks and product dispatch. In KMBN OM405, you'll learn how to coordinate machines, people, materials and methods so a factory becomes predictable, efficient and resilient.
Planning & Capacity Management
Good planning starts with demand forecasting and capacity checks. Use a simple trick: keep a 3-week rolling forecast and compare it weekly to available machine-hours. If forecast > capacity by 10% for two weeks straight, trigger overtime or rework your line balance. Simple capacity cushion = fewer rush jobs and lower cost.
Process Design & Layout
Design for flow: arrange machines to minimize material handling. A small example — moving a press 6 meters closer to the weld station can shave 12 seconds per part; over thousands of parts, that’s hours saved. Cell layouts and one-piece flow are powerful tools for faster lead-time and less WIP (work-in-progress).
Quality Management & Continuous Improvement
Quality isn't an inspection step — it's built into the process. Encourage operator checks, poka-yoke (error-proofing) fixtures, and quick PDCA cycles. Keep a visual board with defects by type; prioritize the top 3 — fix one small root cause every week. Over time, small wins compound into major cost reduction.
Maintenance Strategies & Safety
Shift from reactive to predictive maintenance. Start with basic preventive tasks: daily walk-around checks, weekly lubrication, monthly alignment. Track MTBF and MTTR — even pen-and-paper records work initially. Safety must be visible: use shadow boards, lockout-tagout, and quick drills to reduce incidents.
People & Team Management
People make systems run. Cross-train operators so any station can be covered for short absences. Use short daily huddles (5–8 minutes) to review goals and bottlenecks. Reward the simplest improvements: a suggestion that saves 10 minutes earns recognition. This builds continuous-improvement culture.
Tools, KPI & Quick Tricks
Use OEE (Overall Equipment Effectiveness), cycle time, and yield as core KPIs. Quick trick: pick one bottleneck machine and measure its OEE for 2 weeks — then focus improvement there. Small changes to setup time, or a cleaning routine, often give the best ROI. Keep documentation short and visual — one-page SOPs work best on the shop floor.
If you'd like the full PDF notes, solved examples, and a performance-report template used in this course, click the download button below or chat with our team for tailored help.
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