Lean manufacturing principles
Implementing the principles of lean manufacturing is fundamental to optimizing factory operations. This approach focuses on eliminating waste, improving process flow and continuously increasing productivity.
The second Lean Conference was held in Iskraemeco, Egypt, in early June. Colleagues from India, Malaysia, Egypt and Slovenia discussed key performance indicators to be used and implemented for continuous improvement of production and related processes. One of the topics was the 5S method for creating and maintaining a clean and productive workplace. Participants learned about different methods and how they can use this performance indicator for future improvements when discussing the efficiency of their facilities.
Advanced automation and robotics
Automation and robotics have revolutionized factory operations and offer significant advantages in terms of speed, precision and cost efficiency. Using automated systems for repetitive tasks and implementing robots on assembly lines increases productivity, reduces human error, and improves workplace safety, allowing workers to focus on higher-value tasks that require creativity and problem-solving skills.
Iskraemeco Kranj recently upgraded the versatility of its three-phase lines, which previously supported only residential stand-alone meter (RSA) segments. After a successful upgrade, these lines can now also produce products for the RSM (residential smart meter) market. In the coming months, additional improvements will be installed to increase capacity, productivity and reliability. The upgrade of the three-phase automated line will include the implementation of two robotic cells, while the upgrade of the single-phase automated line will focus on supporting IE.5 and simplifying changeovers.
Employee training and engagement
Investing in the training and development of factory employees is essential for operational excellence. We know that only well-trained employees understand their roles, have the necessary skills and are able to adapt to changing requirements. Encouraging employee engagement through regular communication, feedback channels and recognition programs fosters a positive work environment that leads to increased productivity, better morale, and lower turnover.
Having the right people in the right places is increasingly important. Each of us is responsible for the quality of our own work. As products become more complex, employees’ skills must be regularly updated to ensure they have sufficient knowledge to do our jobs. In order to provide a safe environment for production employees to improve their skills, we intend to build a special training center near the production facility. Specialists from Iskraemeco and other companies will be able to pass on their knowledge to other employees in this training center.
Data analytics and continuous improvement
Harnessing the power of data analytics uncovers valuable insights for enhancing our operations. By analyzing key performance indicators (KPIs), production metrics and quality data, we regularly identify areas for improvement to make data-driven decisions. Continuous improvement methods, such as Six Sigma and Total Quality Management (TQM), increase efficiency, reduce errors and optimize processes to meet our customers’ expectations.
Recently, several improvement workshops were held in which employees from different areas and departments discussed possible causes of deviations and defined measures to eliminate further waste in processes. During these sessions, employees discovered that data quality plays an important role in further analysis. A number of projects were initiated to improve data quality, including a revised methodology for calculating performance indicators, automated performance monitoring, and the like. We believe that better data availability will in-crease our confidence in the performance indicators and that we can use them as the best starting point for further analysis and action.
