Busting Myths of Manufacturing – Keep the Machines running. It’s the Only Way You’ll Make Any Money!

Reality: While machines don’t make money when they’re stopped, they only really make money when what they produce is sold (in the quantities ordered – at a profit) not delivered into stock. Risk: Ideally each machine would be dedicated to produce vast quantities of one part number only without ever stopping to change over to another. In reality… Continue Reading

𝗕𝘂𝘀𝘁𝗶𝗻𝗴 𝗠𝘆𝘁𝗵𝘀 𝗼𝗳 𝗠𝗮𝗻𝘂𝗳𝗮𝗰𝘁𝘂𝗿𝗶𝗻𝗴 – 𝗪𝗲’𝗿𝗲 𝗠𝗮𝗸𝗲 𝗧𝗼 𝗢𝗿𝗱𝗲𝗿 𝗦𝗼 𝗪𝗲 𝗗𝗼𝗻’𝘁 𝗛𝗮𝘃𝗲 𝗧𝗼 𝗥𝗲𝗹𝘆 𝗢𝗻 𝗙𝗼𝗿𝗲𝗰𝗮𝘀𝘁𝘀

𝗠𝘆𝘁𝗵: “We only produce to customer orders. We don’t have to worry about inventory and forecasts.” 𝗥𝗲𝗮𝗹𝗶𝘁𝘆: For manufacturing processes of a few minutes or hours most Planning Systems allow 2 – 3 days each. Taken together these “time off-sets” mean Lead Times to produce a few hours of work are forecasted over multiple weeks.… Continue Reading

𝗕𝘂𝘀𝘁𝗶𝗻𝗴 𝗠𝘆𝘁𝗵𝘀 𝗼𝗳 𝗠𝗮𝗻𝘂𝗳𝗮𝗰𝘁𝘂𝗿𝗶𝗻𝗴 – 𝗧𝗮𝗸𝘁 𝘁𝗶𝗺𝗲 𝗺𝘂𝘀𝘁 𝗰𝗵𝗮𝗻𝗴𝗲 𝗲𝘃𝗲𝗿𝘆 𝗱𝗮𝘆

𝗠𝘆𝘁𝗵: Takt time must change every day to accommodate changes in product mix and volume. 𝗥𝗲𝗮𝗹𝗶𝘁𝘆: Variable Takt time means changing the “line design” i.e. the layout and number of resources and work to be carried out by each should change on a daily basis. This is rarely if ever practical. 𝗥𝗶𝘀𝗸: Orders are batched… Continue Reading

Paying our way in the world

Summary: One third of mid-size British manufacturers are underperforming in critical areas of inventory turns, Cash Flow and Working Capital Management, restricting their contribution to GDP growth and exports. Even though they survived the “great recession” their existence is still at risk over the coming 2 to 5 years. But, it doesn’t have to be… Continue Reading

Myths of Manufacturing – We can only remain competitive if we produce in low-cost countries.

“You can’t have your cake and eat it.” Myth or reality? Back to manufacturing. Don’t we often hear….? Myth: “We can only remain competitive if we produce in lower cost countries, especially with a weaker £ pushing up import costs.” Reality: Lower costs overseas can be more than off-set by higher less quantifiable costs. Risk: Cost of… Continue Reading

Industry 4.0 and Lean 4.0 – What might they mean for you?

“How’re you doing with the revolution, Comrade?” someone asked me the other day. What?!! “The 4th Industrial revolution!” otherwise known as Industry 4.0. Like the rest of us I’d heard about the 1st Industrial Revolution. It started in Manchester, then known as Cottonopolis – but the 4th? Well, we’re actually in it right now. Each one… Continue Reading

flow beyond Lean – Stories from the Lean Edge

Background – Business and the British Economy Lord Digby Jones, a dedicated “Captain of Industry” emphasises in both his books, “Fixing Britain” (2011) and “Fixing Business” (2017) the apparently self-evident fact that, “If it were not for the wealth created by Business there would be no tax revenue, there would be no Public Sector.” He… Continue Reading

𝗕𝘂𝘀𝘁𝗶𝗻𝗴 𝗠𝘆𝘁𝗵𝘀 𝗼𝗳 𝗠𝗮𝗻𝘂𝗳𝗮𝗰𝘁𝘂𝗿𝗶𝗻𝗴 – 𝗜𝗻𝘃𝗲𝗻𝘁𝗼𝗿𝘆 𝗜𝘀 𝗔𝗻 𝗔𝘀𝘀𝗲𝘁

Myth: nventory is an asset” – say the accountants. It adds value to the business. The more the better. Reality: Inventory = your Cash embedded in the business. You can use it as collateral for a loan – at a fraction of book value?   Book value is a fraction of market value, after that’s… Continue Reading

𝗕𝘂𝘀𝘁𝗶𝗻𝗴 𝗠𝘆𝘁𝗵𝘀 𝗼𝗳 𝗠𝗮𝗻𝘂𝗳𝗮𝗰𝘁𝘂𝗿𝗶𝗻𝗴 – 𝗟𝗮𝗯𝗼𝘂𝗿 I𝘀 S𝗼 E𝘅𝗽𝗲𝗻𝘀𝗶𝘃𝗲

Myth: “Labour is so expensive we just have to lay off some (more) people.” Reality: Labour is 10%-15% of most product costs. Overhead is 25%-40% and material 45%-65% of Total Product Cost. Labour only seems expensive because Overhead Absorption is driven by Labour Hours. The Fully Burdened Labour Overhead Rate overstates Labour at 35%-55% of… Continue Reading

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