LCE’s Line Performance Optimization model (also known as LPO) is designed as a comprehensive approach for solving chronic and persistent reliability issues with a specific manufacturing line. This video explains the process and how it delivers ROI for manufacturers experiencing production losses, unplanned downtime, and quality-related issues.
By fully engaging the workforce to ensure long-term sustainability, this lean-aligned model helps clients increase their Overall Equipment Effectiveness (OEE) by an average of five percentage points—delivering a rapid return on investment, as demonstrated by one food manufacturer that eliminated nearly two million pounds of annual waste and uncovered over eight million dollars in total improvement opportunities.
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Are you struggling with production losses or quality related issues on a production line? Are you experiencing unplanned downtime because assets are unreliable?
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LCE’s Line Performance Optimization model, also known as LPO, is designed as a comprehensive approach for solving chronic and persistent reliability issues with a specific manufacturing line.
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Clients using this targeted approach have increased OEE by an average of five percentage points, for example from 70% to 75%, depending on your specific cost-volume-profit equation, the improvement to the bottom line will quickly result in a positive ROI.
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LCE’s LPO is a lean-aligned process that fully integrates proven reliability excellence concepts with selected lean tools, supported by a well-defined organizational change management process that ensures sustainability.
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Implementing the LPO model typically lasts from 6 to 12 weeks and usually includes the following steps.
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We guide you through a value stream mapping exercise that focuses the problem-solving while identifying key loss elimination opportunities.
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This exercise alone often yields quick wins for the team.
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To diagnose inherent failure modes, we perform FMEAs on critical pieces of equipment identified through the value stream mapping exercise.
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We work with your team to develop strategies to eliminate root causes and create equipment maintenance plans to ensure sustainability.
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We work with your team to create best practice processes for start-up, shutdown, and changeover.
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Those processes are then standardized to eliminate variability.
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We add lean visual factory elements to the solution. Visual management boards are implemented on the plant floor so it’s easy to track production results and compare them to goals.
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Critical downtime causes are summarized using Pareto analysis, and then the workforce engages in the problem-solving process to identify corrective actions that will address the root causes.
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We integrate organizational change management throughout the process to fully engage the workforce and gain their active sponsorship and support for the changes in work processes, procedures, and practices that are always a part of the solution.
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This change management component is essential to long-term sustainable results.
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For one food manufacturer,
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this LPO process applied to one line resulted in quick wins in the value stream mapping phase
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that exposed and addressed 400,000 pounds of annual losses.
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An additional one and a half million pounds of waste was exposed and addressed
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through improving changeovers, operator care, and visual management.
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The overall opportunity for improvement for this one food manufacturer was valued at more than eight million dollars.
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If you’re experiencing a persistent reliability issue on a production line, call us or email us
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to learn how Line Performance Optimization can deliver results for you.