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Perhaps the toughest and certainly the most unremitting challenge facing manufacturers, especially those with capital-intensive processes, is how to secure the highest competitive standards of asset care and process capability.

In many ways the whole business of performance improvement is a matter of squeezing out variation and irregularity from our methods and machines.

This can take time, patience and much attention to detail. But we can make good progress if we can work closely and effectively with production, plant and QA engineers, technicians and production teams, collaborating in such a way as to demystify the 'black art' of processes and the finer points of equipment set-up.

The benefits are that we can get our equipment to really sing; to outperform even the specifications given by the machine suppliers; eliminate breakdowns and errors; reduce scrap, rework and inspection; reduce energy consumption and CO2 emissions and thereby benefit from current carbon regulations rather than fall victim to them; install much more disciplined methods to hike up quality yield and greatly improve our capacity without making further capital investments or launching another shift.

Few labels of best practice manufacturing gained greater currency than TPM (Total Productive Maintenance) and the measurement of OEE (Overall Equipment Effectiveness).

But most factories under-exploit these disciplines to an appreciable extent: OEE is too often poorly understood in organisations, wrongly calculated- and against a weak standard- and rarely used effectively; the full potential for autonomous and preventative maintenance is seldom captured; there is often insufficient attention given to standardising processes- despite a plethora of 'SOP's which frequently amount to little more than administrative paperwork that adds little value.

Forward Vision's expertise in process control and experience of what typically falls flat organisations' best efforts to tackle it can make a big difference. E mail or call the number below to find out how.