"Because
of absenteeism and other unavoidable problems we cannot meet our production schedules.
Is there some way to rectify this?" C.R., Mississippi "Because
of absenteeism and other unavoidable problems we cannot meet our production schedules.
Is there some way to rectify this?" C.R., Mississippi
THE INDUSTRY ADVISOR
STAYING ON SCHEDULE
WITH UTILITIES
By Gene Levine - www.genelevine.com
It’s hard to provide a specific answer to your scheduling problem
because of your many contributors, I.E. "absenteeism and other unavoidable
problems." So, I will share with you one insight gained by my
observing companies who do not have your troubles in meeting their schedules. The common
denominator they all use is Utility Machine Operators ("Utilities") and by using
these Utilities the companies get a bonus; lower costs and higher quality.
A properly conceived and administered professional Utility Operator's Program enhances the scheduling attainment abilities of a factory. Even though most managers agree with the concept of Utilities, they stop at vital cross-training programs leaving only the most progressive companies to take the process to its logical conclusion. A complete in-depth Utilities discussion is beyond the scope of this answer but, I will offer an overview which should help you decide if Utilities can solve your issues.
First, the number of Utilities companies have are usually equal to the absenteeism percentage. For example, if you have 100 machine operators and your absenteeism percentage is 10% you will need 10 Utilities. You will also possibly need extra machinery for those unlikely days when no one is absent.
My experiences have shown that Utilities are too important to allow their selection to be casual. Choices should be more than "good" operators. Never assume that any (high earnings) operator can be a good Utility because, a Utility’s career path could find them developing into a Section Supervisor, Engineer, Operator Trainer or Module Member and as we all know, good ball players do not necessarily make good coaches.
Here are some policies concerning Utilities from the companies that utilize them. Utilities have no "Regular" operation or work place and as such cannot reject being assigned to any operation, anywhere in the factory, any module or any supervisor. Logically therefore, the Head of Production Control should be the Utilities’ immediate supervisor and give them their daily job assignments. Utilities are to achieve a minimum of 90% production, with the necessary quality on any and all jobs they are assigned to. Utilities shall not remain on any one job for more than 16 consecutive working hours. Although responsible to Production Control, Utilities cooperates with each line supervisor or module facilitator where they are assigned.
Utilities are required to use the most preferred methods as set forth by Engineering Department Standards. In instances where any work practices can be improved, Utilities freely make suggestions. Utilities may be often asked to assist the Engineering Department in developing or getting results with new work-aids, methods, machines, people, efficient work practices or other suggestions.
Utilities are required to follow safe work practices while doing their job assignment and have a responsibility to make policy recommendations to the Personnel Department with respect to improving the planning, organization and administration of the Utility program.
Utilities can be utilized to assist in training (or re-training) of machine operators, or work with Line Supervisors to ensure that training methods are relevant to production requirements.
Generally, in companies where Utilities are used, prior to being considered for the Utility program, the companies require interested employees to demonstrate attainment of a sustained 90%+ production level (or more) on 85% (or more) of all manufacturing operations throughout the factory. This may require considerable on-the-job training while potential Utilities become familiar with all the various jobs. The company is responsible to pay for the training of any qualifying operator while learning new operations. Utilities will also be trained in time and motion study procedures and should work closely with the Industrial Engineering Department. You are developing a team of professionals dedicated to keeping the flow of goods going out on-time.
Utilities are trained to set a professional example and standard for all other operators. Their conduct and attitude should be impeccable and one they are personally proud of. Some key examples of what your program should contain are;
1. That prior to being accepted into the Utility program an employee's work record must show that they . . .
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