If your monthly report shows deviations in production, you're too late – and you lack efficiency. The crucial question is: How can production processes be controlled so that quality, reliable delivery and productivity increases at the same time – without overloading the workforce? One answer is shop floor management – a management methodology that brings management to where value is created: directly to the production line.
"In day-to-day business, it’s a challenge to drive strategic development forward. But anyone who wants to optimise processes in the long term must face the reality on site," emphasises the interim manager from Top50!, who supported a client in introducing Shopfloor Management.
After his initial analysis at the customer's site, he recommended, among other things, the introduction of this methodology. It stands for effective leadership and for controlling the value chain directly ; it optimizes production processes, helps to make better use of resources and also to minimize waste.
Four factors that make Shopfloor Management effective:
Leading:
For our client, this was a new way of leading, requiring a shift in mindset. Managers and team leaders are given greater responsibility for how daily routines and processes on the shop floor are organised, monitored, and improved. This includes setting goals, delegating tasks, and coaching employees.
Visualising Key Performance Indicators:
Together with department heads, our interim manager identified the five most important production KPIs. Team leaders can now read the current figures daily from the automated ERP report.
On-site Communication:
A central tool in Shopfloor Management is the board, where team leaders update and visualize key performance indicators every day. The color coding is simple and effective: Blue means the target was exceeded. Green means achieved. Red means: Not achieved—action required. The team meets every morning for a 15-minute exchange. How did yesterday go? Where are the problems? What actions will we take?
Immediate Problem Solving:
Shop floor management enables problems to be identified and solved immediately. In our specific case, for example, it was a lack of material. Thanks to more intensive communication with the purchasing department, there are now fewer missing parts. This also means that relaible delivery to customers can be better maintained.
How Shopfloor Management changes things:
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The first management level actively takes responsibility for processes and results.
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The shopfloor board makes the production status visible on a daily basis.
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Daily short meetings create momentum and solve problems immediately.
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Focusing on the most important KPIs ensures quick responses to deviations.
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Deeply involved employees ensure significantly clearer communication
These changes also occurred at the customer's site — with clear effects on efficiency and collaboration. Before there was a lack of transparency in communication and no clear focus on relevant KPIs.
The introduction of Shopfloor Management has already led to noticeable increases in efficiency. To keep these successes in the long term, the interim manager relies on a clear approach:
"Six months after introduction, we check whether the new routines are anchored in everyday life—only then can we prevent old habits from returning," says the interim manager.
We are happy to support you in making your production processes more efficient and transparent.
Contact us today—and take the first step towards sustainable efficiency
office@top50interim.com or +41 (0)41 412 02 02.
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