PDMP – Process Documentation Maintenance Program
The Productivity Team is excited to introduce a new packaged services offering, PDMP! The Process Documentation Maintenance Program is a packaged service that TPTÂ engineers and business development professionals designed to attack profit drain before a manufacturer is too deep in to a build and a “do whatever is necessary” approach begins to erode profitability.
Why the Need for PDMP:
- Most companies do not conduct predetermined labor and work balancing time studies on a regular basis
- Initial line balancing and labor studies are performed once when a new product is launched or if there is a re-rate in production volumes
- Profit drain occurs when the manufacturer shifts in to production mode. Workarounds begin to occur and that mindset drives non-value-added work, poor OEE, and reductions in First Run Through
Benefits of PDMP:
- Improved metrics on First Run Through
- Right-sized Indirect and Direct Labor to support production
- Continuous focus on elimination of non-value added activities
- Increased OEE
- Meaningful impact on monthly P&L
- Increased moral on the line
What Does PDMP Include:
- Video of current manufacturing/assembly operations for MODAPTS time study analysis
- Process validation of your current state operations and process control including: PFMEAs, Control Plans, Work Instructions, Standardized Work and PFEP
- Current State line balance highlighting Value Added, Non-Value Added, Non-Value Added but Necessary Work and GoldenZone analysis for each operation
- A re-balance of the current state operations focused on the elimination of NVA activities and rightsizing of direct and indirect labor to support future state
- Update of all process documentation and quarterly reviews to continue to drive process and productivity improvements
- Quarterly on-site reviews and process document updates to continuously focus on waste elimination and labor efficiency
