Above was a
best case scenario. Consider a bottleneck with 20
downstream employees affected. Add in Engineering,
material handlers, more management/supervisors,
controller, safety personnel, accounting, secretaries,
rework, and offsite QC inspections. You could include
the offsite personnel cost like consultants, OEM
techs, etc., but it is recommended to have those costs
in their own category as they are so great. Think
about if the entire plant was shut down. How much
would the TDC labor cost alone, be? You may
re-prioritize the main breaker switch or air
compressor PM.
Looking for the
overlooked
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Details
of the individual metrics within each of the
main downtime cost categories would be out of
the scope of this article. I hope you find the
list below to have some useful information and
tips. The object is to stimulate the creative
thinking process and help you realize areas that
might otherwise be overlooked. It
is recognized that there is a great deal of
uncertainty and scientific difference of opinion
surrounding the metrics of manufacturing cost
analyses. This list is provided as a starting
point for improving manufacturing cost analysis. |
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