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At PIMS, we obtain comprehensive data for each manufacturing plant and this data set forms the basis of our analysis. The input data can be categorised into the following:
- Scale, complexity & configuration: Annual throughput; variety handled (e.g. number of unique SKUs, components); mode of raw material receipt; automation.
- Operations: Overall Equipment Effectiveness (OEE); batch size; capacity utilisation; energy efficiency; Right First Time and On Time In Full (OTIF)
- Cost and personnel structure: People costs (e.g. salaries, wages, contractor fees, pension funds etc.); non-people costs (energy & utilities, rents & permits, maintenance services, catering, etc.).
Analytics Software
The comprehensive Analytics Software yields answers to questions such as:
- What are the cost thresholds to produce and dispatch a unit of finished product in my region and what is my delta to regional best practice peers?
- What is the optimal number of Full Time Equivalents (FTEs) for a plant of my scale, automation and complexity? How can I make operational changes to drive labour productivity?
- How can I improve the utilisation rates and minimise the planned/unplanned downtime of my assets to boost OEE?
- How many units (kWH) of energy am I consuming to produce a unit of finished product versus look-alike operations? How much am I paying per unit of energy versus local competition?
- What is the optimal balance of preventive/reactive maintenance?
