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Ask the machine operators directly what is wrong and what keeps them from increasing production. Most of the time their supervisor has too many people to know all of the problems. Go straight to the experts; ask your operators. Remember, you will not have to if you put them on an incentive program. The only thing you will have to worry about is them being in your face when the machine goes down, every time, without exception.
Questions to ask machine operators:
- What machine in your opinion seems to have the most problems or needs to be repaired to reduce down time?
- Which machine is the best to run, easiest for you to do your job?
- Which machine is the most productive (least down time)? Why do you say it is the best to operate?
- Is there a piece of equipment still used in production that everyone knows has problems but is difficult to fix? Which machine is it? Does it cause specific problems in the manufacturing process? Does it require a longer time to make anything?
- Are there any machines that you think are particularly dangerous to operate? If you can think of any, why do you have this opinion?
- Do you know a machine or piece of equipment that repeatedly has problems that cost the company because of ruined product, increased scrap, slow speed or possibly delayed response?
- Do we have a machine that very few people can run? Is it because it has problems, or is missing a training manual, or the machine needs constant maintenance, stops on its own, ruins product, etc.?
- Which machine ruins or causes the most problems during the manufacturing process? Do you think it is the machine itself or the lack of operator training?
- If you offered an incentive program running this machine and you made more money the faster it ran, what would you ask to be fixed on the machine?
- If you are offered an incentive program and this is not the machine you want to run, what type do you prefer and know you will make more money?
- Did you know we also have an award program where we are introducing that rewards employees that point out problems with our machines?
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