A clear policy to problem solving and escalation placed in shopfloor, maintenace, Tool shop, Industrial Engineering and management. Something like, in case of shutdown, TPM empowered operators have 5-10 minutes to restart the line and inform maintenace to be prepared . If they fail, Maintenace guys are in charge and have 30-60 minutes to deal with, and send a call to Process/Automation Engineers responsible to the line as well as management in order to be prepared. Engineers in charge have 3 to 6 hours to deal with the problem. In case of fail, send a call to the manufacturer with ALL diagnosis done. In every step If succesfuly accomplished, the problem solving and solutions must be documented tô bem part of troubleshooting handbook.

When a production line stops unexpectedly, swift and precise communication is essential to minimize downtime. Immediate notification to key team members, such as operators and maintenance staff, ensures a quick response. Clear identification of the issue prevents confusion, enabling the right personnel to address the problem efficiently. Continuous updates during the process keep everyone informed, facilitating better coordination. This helps prevent further complications and ensures the right resources are deployed. Ultimately, effective communication ensures a prompt and organized response, reducing downtime and restoring production as quickly as possible.

Just start the announcement with a clear definition of problems with a person who is responsible for the resolve of those issues immediately for the line station where stoppage happened.

To manage production halts effectively, establish immediate communication protocols, use real-time communication tools, create clear channels, foster open communication, use visual aids for clarity. Prioritize safety and health communications, and reinforce emergency protocols. Acknowledge the situation, use mobile platforms for instant messaging and notifications, and encourage feedback from frontline workers. Regular updates reduce uncertainty and anxiety among employees. Implement digital signage or traffic light systems for clear communication. Prioritize safety and health communications, and ensure employees are aware of emergency procedures for equipment failure or unsafe conditions.

clear chain of command, centralized communication tools and regular briefing, combining these strategies, organizations can streamline communication, reduce response time, and effectively address production disruptions.

The key is broadcasting real time information to where the work is being done. Connecting people to the right data so they can make the best decisions in the moment. Change can happen quickly with proper communication channels!

Implementing Gemba Management with Horensho communication is effective in manufacturing, especially production lines. When production control is carried out in Gemba using visual management, where any discrepancies can be quickly detected and reported hierarchically. It is not only a matter of reporting but the rules for making the production line run according to the rules that have been set are carried out with real, actual and real-time control. All management is involved in daily operations in Gemba Management, with clear and hierarchical reporting criteria. Hierarchical by empowering all managerial levels. From operator-line group-foreman-supervisor-mamager-general manager-to top management. All focus on Gemba (real production line).