Guest expert
Geoff Ellis
Chief Operating Officer at Wherefour, Inc., with public-profile experience in high-growth P&L leadership and M&A integration.
A finished batch can hide what it took to make it. Rework may save the product, but the bill does not stop at the material. In this conversation, Geoff Ellis, COO of Wherefour, looks at how plants misjudge the cost of rework, and why the usual way of counting it can be wrong in both directions.
In this conversation
- When does a rework hour really cost you a sale, and when does it not?
- What does a batch quietly consume on its second trip through the line?
- Why can a healthy monthly yield still hide the problem?
- Where does an “accepted” loss stop being acceptable?
Who should watch
Plant managers, operations managers, production and process engineers, continuous improvement leads and finance partners in food and beverage manufacturing who report yield, approve rework or set production standards.
Topics covered
- Yield standards and theoretical yield
- The full cost of rework in a food and beverage plant
- Material loss and lost production capacity
- Short line stops, first-pass yield and changeover time
- Comparing results by line, shift and run
- Choosing which losses to investigate first
Chapters
- Small production stops and lost capacity
- What rework consumes
- Costing rework with and without a capacity constraint
- First questions for a production review
- Unavoidable loss and accepted loss
- Segmenting yield by line, scale, shift, or supervisor
- Relating measures to map leakage
- Mapping process steps and handoffs
- Choosing data people can act on
- Prioritizing the work
- Rechecking plant standards
Included with the full course
The full course includes four video lessons, the 40-page ebook Financial Hemorrhage on the Factory Floor: Identifying and Eliminating Waste Leakage in North American Food and Beverage Manufacturing, and two tool sets: the food and beverage 5 Whys template bundle and the F&B Plants Root Cause Analysis workbook and forms pack. Buying the course gives lifetime access to all of it. The whole course is also included with the CPAI Premier, Premier Team and Premier Factory access plans.
Lesson 1 of 4 | 36:56 | In English | Hosted by Saeed Sarfarazi
