Automation
TECH FLASH

Outsource production maintenance?

Chris Adderton
Chris Adderton. Source: ATS.

“Simply stated, food processors are under the gun to produce compared to other industries,” says Chris Adderton, Advanced Technology Services (ATS) senior account manager, consumer packaged goods. “When comparing cycle time of food processors to overall discrete manufacturing plants, food manufacturers have the shortest cycle time at a median of five hours. Compare this to a median of 18 hours at other manufacturing plants.” Food processors maintain a higher on-time delivery rate of 98 percent compared to 95 percent of other industries, and it’s easy to see why they hardly have time to breathe, according to Adderton. (These data are based on findings from the Manufacturing Performance Institute.)

The cycle of reactive activity puts food processors at a distinct disadvantage with the lowest median machine availability of all manufacturers surveyed at 83 percent, according to Adderton. In addition, food manufacturers are the most likely to increase output in 78 percent of the plants surveyed.

The demands of increased output require investment in machinery and technology and the skilled labor to operate and maintain them. And unlike manufacturers of the past, not all manufacturing functions are considered core, says Adderton. “In fact, clearly 96 percent of all food manufacturers outsource some functions already, and many more are considering outsourcing maintenance.”

The benefit of selecting a professional outsource provider can put a production-constrained food manufacturer on the path to lean manufacturing quickly, according to Adderton. This can be accomplished systematically through establishing metrics for OEE, machine availability and meantime between failures—to name a few. All of these key metrics, coupled with a proactive culture brought to bear by an outsource provider, can have a dramatic impact on productivity, adds Adderton. “In fact, it is not uncommon to see manufacturing output rise by 30 percent or greater. And in a capacity-constrained business, that adds up to changes you can measure in dollars and cents with more product out the door faster.”

Outsourcing production maintenance also helps provide a solution for the shortage of skilled labor currently found in maintenance organizations, according to Adderton. In a recent survey sponsored by ATS through Nielsen Research, 46 percent of manufacturing executives surveyed said finding skilled maintenance professionals was the most difficult of all positions to fill. Additionally, 70 percent said production maintenance was very important in achieving lean manufacturing. In addition, the same group said that of all activity that can increase productivity in manufacturing ahead of improved safety and new equipment, maintenance ranked number one.

For more information, contact Chris Adderton at 847-909-4958 or via email.

Did you enjoy this article? Click here to subscribe to Food Engineering Magazine.

You must login or register in order to post a comment.

Multimedia

Videos

Image Galleries

IPPE 2015

The 2015 International Production and Processing Expo (IPPE) was held in Atlanta at the Georgia World Congress Center, Jan. 27-29. More than 30,000 poultry, meat and feed industry representatives attended the event to interact with the 1,288 exhibitors on the show floor that covered more than 490,000 net square feet. At the show exhibitors demonstrated innovations in equipment, supplies and services utilized by firm in the production and processing of meat, poultry, eggs and feed products.

Podcasts

Burns & McDonnell project manager RJ Hope and senior project engineer Justin Hamilton discuss the distinctions between Food Safety and Food Defense as well as the implications for food manufacturers of the Food Safety Modernization Act.
More Podcasts

Food Engineering

Food Engineering February 2015 Cover

2015 February

In this February 2015 issue of Food Engineering, we explore how energy waste caused by leaks in compressed air, steam and water or faulty building insulation/seals can be reduced with the right equipment and knowledge.

Table Of Contents Subscribe

FSMA Audit

What is the is most important step you have taken to become ready for a FSMA audit?
View Results Poll Archive

THE FOOD ENGINEERING STORE

Food-Authentication-Flyer-(.gif
Food Authentication Using Bioorganic Molecules

This text provides critical tools and data needed to augment routine food analysis and enhance food safety by aiding in the detection of counterfeit, and potentially deleterious, foods.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications,Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.

STAY CONNECTED

FE recent tweets

facebook_40.pngtwitter_40px.pngyoutube_40px.png linkedin_40px.pngGoogle +

Food Master

Food Engineering Food Master 2015Food Master 2015 is now available!

Where the buying process begins in the food and beverage manufacturing market. 

Visit www.foodmaster.com to learn more.