What is Centerlining?

Centerlining is a methodology that focuses on using established process settings to ensure consistent shop floor operations. In manufacturing, it works to decrease product and procedure inconsistencies by optimizing machine effectiveness.

Centerlining serves two primary purposes: 1) identifying which machine settings are needed to best perform a production process and 2) making sure operators implement those settings at all times to prevent product defects.

The type of machine settings that can be centerlined to develop high-quality goods range from speed, temperature, and humidity settings to guard rail alignment and accurate pressure points. Activating the correct equipment settings can help standardize procedures throughout all operations and reduce production waste.

Centerlining works in tandem with total productive maintenance (TPM), a widely used methodology for enabling workers, equipment, and supporting processes to preserve and enhance the safety, quality, and integrity of production in manufacturing.

Learn more about centerlining, its relationship with TPM, and its benefits by exploring the following questions:

What is a centerline in TPM?
What are the benefits of centerlining?
What are some tips for implementing centerlined processes?

What is a centerline in TPM?

Centerlining, also called run-to-target, works by using standardized machine settings per product — equipment speed, pressure, temperature, etc. — to guarantee a consistent operational process throughout each production run.

Using the correct centerline settings gives employees a better idea of which process variables need to be controlled to increase quality product output.

In return, workers must know which process variables are causing delays in production to correct the problem. A statistical process control chart can be used to pinpoint which variables are causing issues in production. This makes it easier for operators to gauge what works and what doesn’t to make necessary changes and ensure continuous improvement through each product cycle.

Centerlining is especially critical during changeovers on the shop floor. When one product run has finished and operators must switch their equipment to accommodate a different product, the faster and more accurately this happens increases productivity and reduces waste overall.

A manufacturer that has implemented TPM can fully reap the benefits of centerlining on the shop floor. Without a successful TPM approach, operators are left guessing on how to properly set up a machine. This causes longer changeover times, lower productivity, and more waste.

TPM places the responsibility of regular machine maintenance on the operator to ensure that there are no equipment breakdowns, stops, slowness, defects, and accidents. Essentially, they are in charge of maintaining their own machines to reduce workplace losses. TPM is a fundamental principle of the Toyota Production System.

If operators are unsure how to properly manage their machines, applying even the best of centerlining methods won’t matter. This is because centerlining is contingent on how well they know their equipment and operating procedures.

Learn more about TPM and how it can benefit your operational processes.

What are the benefits of centerlining?

Applying centerlining in manufacturing not only boosts the quality of each product, but can also enhance workplace safety, decrease waste, and reduce production delays.

Some other benefits include:

Real-time insight: Gauge how a current process is performing and identify what centerline setting is causing problems.
Short-term analysis: Receive input on which products thrive under certain settings and which need improvement.
Long-term review: See which process variables have changed so you can troubleshoot equipment issues more quickly.

What are some tips for implementing centerlined processes?

Creating consistent, quality products is a must to ensure customer satisfaction and retain clients. That’s why inspecting goods after they are made is crucial before distribution.

A 100% product inspection, however, may be difficult to achieve given the variety and volume of products a manufacturer outputs. This is where centerlining can help. By making sure that each process is carried out the same way each time, you’re virtually assured of reaching a consistent production cycle.

You can centerline any process by following four steps:

Determine the key variables of a process (materials used, machine breakdowns, etc.).
Identify which settings need to be used for all variables to create quality products (such as machine speed, temperature, pressure, etc.).
Evaluate how each variable affects the production process and product output.
Ensure the correct centerline settings are always applied during each assembly run.

Learn more about each step and how to centerline a process in our helpful guide on how centerlining improves efficiency in manufacturing.

Augmentir offers digital solutions to centerline processes and identify which variables are causing disruption to your production line. Our connected worker solution provides easy-to-use navigational tools to streamline procedures and ensure high-quality goods.

Explore our safety and quality use cases to meet product compliance standards and minimize errors. Request a live demo to begin optimizing your frontline operations!

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