How to Track Processes in U.S. Manufacturing

Metrics don’t make the difference. The right metrics make the difference. Operators don’t need 40 KPIs. You need one page for throughput, quality, speed, options, resilience. The six metrics in the graphic are that page. Here’s how to turn them into decisions this week: Start now 1️⃣ Queue Length → Track waiting work at each step (sales, design, QA, shipping). ↳ Quick math: Cycle time ≈ WIP ÷ throughput 🧠 ↳ Trigger: any step >1.5× its 4‑week median for 3 days. ↳ Move: set WIP limits and swarms to unblock. 2️⃣ Rework Rate → Rework ÷ total completed. First‑pass yield is 1 − rework. ↳ Split by source (spec, process, training). ↳ Move: add checklists; pair review the top 3 drivers. 3️⃣ Escaped Defects → Customer‑found issues, by severity. ↳ Add “time to contain” alongside the count. ↳ Move: pre‑release check gates; fix‑forward playbooks. 4️⃣ Time to Decision → Days from issue to committed choice. ↳ Classify by decision type: reversible vs one‑way door. ↳ Move: set SLA by level (e.g., L1 24h, L2 3d) and escalate. 5️⃣ Option Value Created → Count rights without obligation: second suppliers, alternate channels, modular parts, cancellable contracts. ↳ Also track cost to hold and shelf‑life. ↳ Move: kill stale options monthly. 6️⃣ Buffer Coverage → Days of cash runway, critical inventory, and redeployable capacity within 1 week. ↳ Guardrails: min to survive, max to avoid drag. ↳ Move: pre‑plan cuts and pivots so buffers buy time. 💡 Cadence → 30‑minute weekly “Flow & Faults.” ↳ Look left‑to‑right: queue → rework → defects → decisions → options → buffers. ↳ Ask: Where are we stuck? What changed? What will we try? 💡 Anti‑gaming pairs → Queue Length with Throughput. → Rework with First‑pass yield. → Escaped Defects with Time to contain. → Buffers with Opportunity cost. 💡 Fast setup → Start in a spreadsheet or your current tool. ↳ Pull counts from boards, CRM, ERP. ↳ Keep one‑click charts; talk trends, not decimals. This is the playbook operators and founders use to ship under stress—what Operating by John Brewton breaks down weekly with checklists and case studies. ✅ Define each metric for one product or team and set a trigger. ✅ Build a one‑page view and schedule the weekly review. ✅ Make one change per week from what the metrics tell you. ♻️Repost & follow John Brewton for content that helps. ✅ Do. Fail. Learn. Grow. Win. ✅ Repeat. Forever. ⸻ 📬Subscribe to Operating by John Brewton for deep dives on the history and future of operating companies (🔗in profile).

"The best tool for debottleneck identification" Value Stream Mapping (VSM) is a way to visually map out all the steps involved in creating a product or service, from start to finish. It helps you see how materials, information, and tasks flow through the process, so you can spot any delays, inefficiencies, or waste. Imagine it like creating a detailed map of a journey, showing each stop and the time it takes to get there. In VSM, you’re mapping out the steps in your production or service process, showing how long each step takes, how much inventory or work is waiting at each step, and how information moves between steps. Here's how VSM works: ✍ Current State Map: First, you draw a picture of how things currently work. This includes everything from the time materials arrive to when the final product or service is delivered. You’ll also track things like how long each step takes and how much inventory is building up between steps. ✍ Future State Map: After seeing how things work now, the next step is to create a map showing how you want the process to look after improvements. This focuses on eliminating waste and making the process flow more smoothly. ✍ Materials and Information Flow: You also track how raw materials and information move through the process, helping to highlight where delays or miscommunication may be happening. ✍ Process Steps: Every task or step in the process gets broken down, and you identify which ones add value to the product or service, and which ones don’t (those are the ones you want to fix or remove). ✍ Metrics: Along the way, you gather key numbers—like how long things take, how much inventory builds up, and how quickly things need to move to meet customer demand. Why Use VSM? 📌 It helps you identify waste, like long wait times, excess inventory, or unnecessary steps. 📌 It can lead to faster delivery times and a smoother, more efficient process. 📌 It makes it easier to communicate and share ideas about improving the process with your team. VSM is widely used in manufacturing, but it works for any business or industry that has a process to improve.

𝐌𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠 𝐥𝐞𝐚𝐝𝐞𝐫𝐬: 𝐲𝐨𝐮𝐫 𝐧𝐞𝐱𝐭 𝐩𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐯𝐢𝐭𝐲 𝐥𝐞𝐚𝐩 𝐡𝐢𝐝𝐞𝐬 𝐢𝐧𝐬𝐢𝐝𝐞 𝐚𝐠𝐞𝐧𝐭 𝐦𝐞𝐦𝐨𝐫𝐲. Factories generate context continuously, but agents forget between every shift. Memory turns isolated events into patterns that optimize throughput and quality. Start with five memories, tuned for safety, quality, and uptime. ↳ Procedural memory standardizes changeovers, capturing tacit expert adjustments precisely. ↳ Episodic memory links alarms to fixes, accelerating root-cause investigations. ↳ Preference memory respects machine-specific tolerances and environmental constraints automatically. ↳ Semantic memory embeds material specs, enabling compliant substitutions under pressure. A Manufacturer's scrap spiked whenever new operators handled line changeovers. Built a procedural playbook with episodic notes from prior runs. Working memory tracked current lot, humidity, and tooling wear in real-time. The agent recommended offsets and verified steps before allowing ramp-up. Scrap dropped twenty percent, and changeover time fell by thirty percent. Maintenance benefited when episodic histories surfaced recurring vibration patterns instantly. Planners used semantic specs to approve alternate suppliers without delay. Safety improved because procedural gates blocked unverified steps under fatigue. Map your bottleneck process, then attach memories to decisions and handoffs. Pilot on one line for two weeks, measure scrap rigorously. ♻️ Repost to your LinkedIn empower your network & follow Timothy Goebel for expert insights #AIAgents #Manufacturing #Construction #Healthcare #SmallBusiness

Step-by-step guide for implementing a Manufacturing Execution System (MES): Define Objectives and Scope: Clearly outline the goals of MES implementation, such as improving production efficiency, enhancing quality control, or streamlining data collection. Determine the specific areas of the manufacturing process that will be affected. Assess Current Systems and Processes: Conduct a thorough review of existing systems (e.g., ERP, SCADA, PLCs) and manufacturing processes to identify integration points, gaps, and areas for improvement. Choose the Right MES Solution: Select an MES software that fits the business needs, has flexibility for future scaling, and can integrate with existing systems like ERP, SCADA, and machinery. Create an Implementation Plan: Develop a detailed project plan that includes timelines, milestones, resource allocation, and roles. Define the hardware and software requirements, network infrastructure, and data storage solutions. Data Preparation and Mapping: Prepare and organize manufacturing data such as equipment details, production recipes, and work order structures. Map this data to the MES system to ensure proper alignment of production processes. Pilot Testing: Implement the MES on a smaller scale or specific production line to test its functionality, integration with other systems, and the overall process. Identify issues and make necessary adjustments. Integration with Existing Systems: Ensure seamless integration between the MES and existing systems like ERP, PLM, SCADA, and equipment for real-time data exchange, workflow synchronization, and reporting. Training and Change Management: Train operators, managers, and IT staff on how to use the MES. Implement change management strategies to ensure smooth adoption and address resistance from the workforce. Go Live and Monitor Performance: Once the pilot test is successful, gradually roll out the MES across the entire plant or organization. Monitor the system’s performance closely to ensure it meets the set objectives and troubleshoot any issues. Continuous Improvement and Scaling: Regularly assess the MES’s performance and gather feedback from users. Continuously improve processes and look for opportunities to scale the system to accommodate more advanced functionalities or additional facilities.

How real-time machine monitoring improves efficiency and reduces downtime. In manufacturing, knowledge is power. The ability to track machine performance in real time is no longer a luxury—it’s a necessity for improving efficiency and minimizing costly downtime. Here’s how real-time machine monitoring is transforming production: 1. Instant Detection of Anomalies Advanced sensors and monitoring software allow manufacturers to track key parameters like temperature, pressure, and cycle times. Any deviation is immediately flagged, preventing minor issues from becoming major problems. 2. Predictive Maintenance Instead of relying on fixed maintenance schedules, real-time data helps predict when a machine actually needs servicing. This prevents unnecessary downtime while reducing wear and tear on components. 3. Data-Driven Optimization Manufacturers can analyze production trends over time, making precise adjustments to optimize performance. Whether it’s fine-tuning clamping force or injection speed, real-time data provides actionable insights for continuous improvement. 4. Better Energy Management Monitoring energy consumption in real-time helps manufacturers identify inefficiencies and adjust machine settings accordingly. This reduces operational costs while making production more sustainable. 💡 Interesting Fact: Research shows that real-time monitoring can reduce unplanned downtime by up to 50%, leading to significant cost savings and improved machine lifespan. 💡 Takeaway: Running an injection molding machine without real-time monitoring is like flying blind. When you have live insights, you can optimize every aspect of production, reducing downtime and increasing profitability. Curious about how real-time monitoring could benefit your operations? Let’s discuss how data-driven manufacturing can improve efficiency in your production. #SmartManufacturing #Industry40 #Efficiency