Technical Director

Understanding Tom's challenges
Directeur technique

​​​​Tom is looking for a clear and effective strategy to eliminate inefficiencies and reach optimal production capacity while maintaining a high level of quality.

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• Increase production capacity : Raise output from 150 to at least 180 units per minute while maintaining product quality.

• Reduce downtime : Minimize breakdowns by implementing effective predictive maintenance and improving team responsiveness.

• Lower the rejection rate : Reduce the rejection rate to below 2% to limit material losses and ensure product compliance.

• Optimize changeover times : Reduce changeover duration from 20 minutes to under 10 minutes per operation to maximize effective production time.

• Strengthen cross-functional coordination : Improve communication and collaboration between departments to enable faster and more effective decision-making.

• Real-time performance monitoring : Implement monitoring tools to analyze performance and adjust line parameters in real time.

The key role of the technical coordinator at FSE INDUSTRY in supporting the success of the Technical Director

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1. Initial analysis and priority setting​

Auditing existing processes is a crucial step in identifying areas for improvement on a production line. This involves a detailed analysis of current performance, including actual capacity, rejection rates, downtime, and format change durations. This analysis helps pinpoint bottlenecks and critical issues that hinder efficiency. At the same time, reviewing historical data helps identify recurring causes of breakdowns and slowdowns. Engaging with operators is also essential to understand the difficulties they face on the ground and to gather improvement suggestions based on their hands-on experience.

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Once this information has been analyzed, actions must be prioritized. In collaboration with the Technical Director, strategic objectives should be defined, whether the goal is to increase production capacity or reduce equipment failures. Each improvement initiative must be accompanied by measurable and realistic goals, such as reaching a throughput of 180 units per minute within six months. This structured approach enables progressive performance optimization while maintaining quality and operational reliability.

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2. Increasing production capacity​

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Optimizing machine parameters is a key step in enhancing production line performance. In collaboration with automation teams, it is vital to fine-tune equipment settings, particularly by optimizing speed and throughput. This approach allows the full potential of the machines to be leveraged while ensuring process stability and product quality. Identifying underperforming equipment also helps anticipate potential malfunctions and implement suitable technical improvements.

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Simultaneously, operator training plays a decisive role in performance optimization. By sharing best practices and reinforcing their understanding of machine settings and limitations, operators become more autonomous and responsive to production changes. A well-trained team can prevent errors, limit unplanned downtimes, and ensure smoother, more efficient production.

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Finally, evaluating the equipment fleet may reveal the need to add or replace certain machines. When optimizations alone are not enough to achieve performance goals, it becomes relevant to explore investment opportunities to modernize or automate critical stages of the process. This approach not only boosts productivity but also enhances reliability and reduces long-term costs.

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3. Reducing downtime

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Implementing predictive maintenance helps anticipate failures and maximize equipment availability. Installing IoT sensors enables real-time monitoring of machine status and early detection of wear or anomalies. Combined with Computerized Maintenance Management System (CMMS) software, this setup facilitates maintenance scheduling before breakdowns occur, thereby reducing unplanned downtime and improving system reliability.

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In parallel, enhancing team responsiveness is critical to minimizing the impact of technical incidents. Setting up real-time alert processes ensures immediate notification to the relevant teams in case of malfunction. Additionally, creating a clear and structured protocol for diagnostics and interventions significantly reduces the time required to identify and resolve issues, ensuring rapid production recovery.

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4. Lowering the rejection rate​

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Analyzing the causes of rejections is a fundamental step in improving production quality. This involves collecting and examining data on non-compliant products to identify recurring defects. The process includes evaluating parameters that influence quality, such as raw materials, machine settings, and production conditions. A thorough understanding of these elements enables accurate targeting of non-conformity sources and the implementation of appropriate solutions.

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To optimize quality control, it is beneficial to automate in-line inspections using technologies such as machine vision and smart sensors. These tools allow faster and more precise anomaly detection, reducing human error. Additionally, technical or organizational adjustments can be made to enhance inspection reliability and minimize production deviations.

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Finally, training teams on quality standards is crucial to reducing rejections. Raising operator awareness of compliance criteria and helping them understand the cost implications of non-conformities fosters a strong quality culture. Better team engagement in meeting quality requirements contributes to the sustainable improvement of industrial performance.