06Operations
Commissioning is the start, not the finish.
Stable production depends on planning, quality, maintenance and traceability systems running from the first batch.
Systems
Operating systems to put in place.
Production Planning
Convert demand into a realistic, sequenced production plan.
SOPs & Work Instructions
Document how each operation is performed and verified.
Operator Training
Qualify people against the work they perform.
Supplier Qualification
Approve suppliers before they are relied upon.
Incoming Inspection
Verify material before it enters the process.
In-process Inspection
Detect deviation while it can still be corrected.
Final Inspection
Confirm product conformity before release.
Corrective Action
Address causes, not just symptoms, and confirm effectiveness.
Calibration
Keep measuring equipment trustworthy and traceable.
Maintenance
Plan machine attention instead of reacting to breakdowns.
Spare Parts
Hold the parts that protect critical uptime.
Traceability
Link material, process and product records.
Safety
Design safe work into the process and the layout.
Metrics
What to measure.
Figures shown are illustrative examples only.
Capacity Utilisation
72%
First-Pass Yield
94%
Rejection Rate
2.1%
Machine Uptime
88%
Overall Equipment Effectiveness
61%
On-Time Delivery
91%
Changeover Time
38 min
Customer Complaints
3 / quarter
Energy per Unit
1.8 kWh