Less is more manufacturing productivity

Recollections of an memorable project

Thinking about the concept of “less is more”, takes me back to a small and initially unpromising project that a maverick boss of mine persuaded me to get involved in many years ago. It provides an interesting example of counter-intuitive optimisation.

The scene…

There was a manufacturing plant which produced credit cards. The plastic cards were manufactured in sheets; this involved a lamination process which started with a “layup” of three plastic sheets and ended up with them laminated together as one sheet. The lamination was done in a press which was heated and then cooled; this caused the plastic sheets to melt slightly and to become welded together as one.  To produce cards with flat and clean surfaces, each layup also had shiny metal plates on either side to produce a smooth finish.

The instinct … Continue reading “Less is more manufacturing productivity”