We can help drive success though these key services:
PEOPLE · TRAINING · PERFORMANCE · LEADERSHIP AND COMMUNICATION · CREWING STANDARDS · CUSTOMER SERVICE |
EQUIPMENT AND FACILITY · CAPACITY PLAN AND UTILIZATION · ZERO-BASED DOWNTIME · PREVENTIVE MAINTENANCE · PROCESS FLOW DIAGRAMMING |
PROCEDURES · STANDARDS AND SPECIFICATIONS · HACCP · PRODUCTION TRACKING · REGULATORY COMPLIANCE · SCHEDULING AND CUSTOMER SERVICE |
TRAINING Employee training is the strongest or the weakest link in any change program. The resistance to change is usually inherent with employees because there are too many unknowns or people are suspicious of management’s motives. Locking this asset to positive results includes employee involvement at the earliest stages of any improvement program. M.O.P. Systems develops in house employee training programs that are unique to the skills of the existing employees. It is part of the “making the most with who you have” philosophy that is enabled M.O.P. Systems to become successful at implementing change programs. Keep in mind that adult training programs are unique and differs from classic classroom instruction.
PERFORMANCE Establishing employee performance programs is a key element to success in change programs. Employees what and need to know what is expected of them and how they can accomplish these expectations. Also these expectations need to be clearly work related and understandable if you expect employee buy in and subsequent participation.
LEADERSHIP AND COMMUNICATION Understanding what needs to be done and being able to communicate these expectations to others is significantly different. M.O.P. Systems provides leadership training that focuses on how and what is being communicated and includes a feedback system that assures information is being understood. Establishing a common frame of reference is essential to achieve these goals.
CREWING STANDARDS How do you know you have enough or too many people manning the line? What is the benchmark to determine how many is enough? M.O.P. Systems links machine expectations, process flows and employee responsibility to establish crewing numbers that assure a lean and profitable operation. All crewing standards are based upon ZERO-BASED DOWN TIME (discussed later).
CUSTOMER SERVICE Quantity without quality is not enough in today’s marketplace. The customer is the final determination of whether the company has met expectations (or not). Unfortunately if you rely exclusively upon customer feedback to determine success, you may find it is too late to make changes. The old adage that for every customer who contacts the company to complain, 10 more were unhappy and didn’t complain. That is allot of unhappy customers. M.O.P. Systems facilitates enhanced customer service through internal auditing and field surveys. Asking for feedback before a problem instead of waiting for the bad news is a proactive way of staying ahead of the competition.
CAPACITY PLAN AND UTILIZATION Getting the most out of what you have is a basic tenet for M.O.P Systems. All to often line run rates are based upon what is comfortable or easily achievable in the past. The idea that being busy is the same as getting the job done comes to mind. Where are the stretch goals and how much can you stretch before capital dollars are required. M.O.P. Systems cuts to the heart of the matter and establishes a baseline for plant performance that is determined by mechanical limitations not people or system limitations. This is coupled with ZERO-BASED DOWNTIME tracking to establish a true capacity plan.
ZERO-BASED DOWNTIME Simply put this means that every minute the filling/packaging machine doesn’t run, that is downtime. Whether it is avoidable or not doesn’t matter. In a typical 8 hour shift a machine can run 480 minutes. Lunches and breaks are downtime. Sounds easy but rarely does a company employ such ruthless tactics. By using this method M.O.P. Systems establishes a true baseline that can only be modified by changing the machine or running longer shifts. It avoids the manipulation of productivity numbers that make in-efficient operations look better than they really are. It also clearly identifies when capital dollars are required vs. desired.
PREVENTIVE MAINTENANCE Pay me now or pay me later is what PM is all about. Just like a star athlete, machinery requires care and servicing, if not, it breaks down and usually at the most inopportune times. Good PM programs can stabilize scheduling and enhance customer service. M.O.P. Systems looks at the risk points and puts into place a PM program that will maintain consistency and line performance. Keep in mind that implementation and follow through are everything.
PROCESS FLOW DIAGRAMMING Required for any HACCP plan, process flow diagramming is a list of steps that each product goes through, from start to finish. Process Flow Diagrams clearly documents each step in the manufacturing process clearly identifying line limiters, pinch points, crewing, etc. and can be used to establish standard costing. M.O.P. Systems develops these documents without the need for fancy software programs and special training. Excel based, anyone with Microsoft software can easily modify and utilize this information.
STANDARDS AND SPECIFICATIONS Required for any HACCP program, standards and specifications documentation establishes acceptable ranges for each step in the manufacturing process and documents what the customer expects. M.O.P. Systems can develop these documents and blend them into an organizational structure that is easily understood and used by management and the workforce.
HACCP Hazard Analysis of Critical Control Points is the food industry standard method for determining food safety risks and what is being done to mitigate such risks. With increased awareness of Bio-terrorism and company liability, no food manufacturing facility should operate without an active HACCP plan. Remember that having a documented plan is only part of the requirement, it must be implemented throughout the organization. It takes time and patience to fully train all employees in their role. M.O.P. Systems can assist in the development of a HACCP plan or participate in its implementation.
SOP (STANDARD OPERATING PROCEDURES) Basic documentation of what is expected at all steps of the process is essential for any facility looking to compete in the marketplace. A step by step listing of requirements and expected results keeps employees focused on doing the rights steps, in the right sequence and avoids shortcuts. SOP’s also provide a basis for training of new employees. M.O.P. Systems has 3+ decades of experience writing SOP’s for the food and pharmaceutical industry.
PRODUCTION TRACKING How do you know if you are having a good day if you don’t know how much you are producing during or throughout the day. Production tracking takes on new meaning when it is done on a real time basis. Problems early in the shift are quickly noted and are actionable thus allowing rational management decisions and leadership, rather than reactive management. Knowing Tuesday morning, how well or poorly you did Monday is too late. M.O.P. Systems can assist in developing a short interval scheduling (SIS) system that is unique to your manufacturing operation.
REGULATORY COMPLIANCE M.O.P. Systems has experience with FDA, USDA, AIB, ASI, Kosher and QAI (Organic) audits, compliance, certifications and other documentation.
SCHEDULING AND CUSTOMER SERVICE Meeting customer expectations determines future business. All customers want to be treated like they are the most important client. Sometimes this isn’t possible and sometimes you have to say No and set a realistic timetable for delivery. M.O.P Systems will help you develop a strategy to maintain control of your schedule and still meet customer expectations. Most customers want consistency and reliability first, then cost become a factor.