This list is provided
as a starting point for improving manufacturing cost
analysis.
- Equipment
Cost Category (constants)
- Categories
- Standardize
your data collection categories, learn
from MIMOSA.
- People
- Indirect
labor cost can often be greater than the
more apparent direct labor cost.
- Product
- Made
up of two sub-categories. Cost per Unit,
and Units per Hour.
- Start-up
- Every
time you startup your machine, there is hidden
cost.
- Bottleneck
- Using
a process flow diagram, pre-determine a
bottleneck factor for each asset.
- Sales
Expectation
- Our
goal is always to maintain a 100% capacity
readiness.
- Labor
Cost Category (constants)
- LPP/M
- Does
your LPP/LPU calculations include indirect
labor?
- QC
- Associate
QC cost, re-work, etc. with actual
downtime occurrence.
- Maintenance
- There
is a substantial staff supporting those
one or two who actually do the machine
repair.
- Engineering
- Engineering
costs to support troubleshooting and
repair of machines can slip through the
cracks.
- Management
- Requesting
maintenance, redirecting operators,
reporting to upper level management,
altering production schedules/flow,
administrative tasks, etc.
- Downtime
Cost Category (Occurrence)
- Time
- Are
you tracking when maintenance arrives at
the scene, or when the machine actually
went down?
- Reduced
Production
- Time
and percentage of full capacity equipment
is running a reduced rate due to a
malfunction.
- Scrap
- On
continuous flow systems, scrap related
directly with downtime can be a very
significant cost.
- Band-Aid
- Please
take note that band-aid time estimates,
and amount of times needed to be done are
usually under estimated.
- OEM, Consulting,
Contractor
- Your
interactions with OEMs can be a major cost
factor in downtime as well as other areas.
- Tooling
- Often
classified as a nuisance problem if
allowed to continue, can really add up in
cost.
- Parts/Shipping
- Out
of the parts and procurement fields, the
actual parts cost is the only value
commonly tracked. What about shipping,
locating, rentals?
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