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5 Steps to a Better Manufacturing Productivity and Efficiency

submitted on 14 November 2018
One of the ways businesses can remain competitive and flexible in today’s competitive market is by maintaining a high level of efficiency. This is an approach that can be implemented across the organization, from the company’s offices to sales and distribution. There are multiple ways to improve efficiency too.

In this article, however, we are going to focus more on how your business can improve its manufacturing productivity and efficiency. There are several steps to take in order to get closer to these objectives.

Review the Existing Processes
Evaluation is the key to understanding the current state of your manufacturing line. You cannot make adjustments to the processes inside the manufacturing line without understanding every detail of them first. A thorough evaluation will also reveal hidden issues and problems that can potentially disrupt or ruin manufacturing effectiveness.

The evaluation process should cover more than just the line itself. It needs to also review the workers inside the manufacturing line as well as the machinery and solutions used as part of the process. The more insights you can gather at this stage, the more you will be able to do as you start improving parts of the operations for an improved effectiveness.

Other details that need to be taken into account are communication process and tools, the interaction between different sections of the manufacturing line, monitoring abilities, and information technology supporting the manufacturing line, particularly systems designed to feed manufacturing data to the rest of the company.

With a thorough evaluation done, it is time to move on to the next step.

Make Adjustments to the Process
The first and easiest part of the manufacturing line to improve is the process itself. You can alter the way the manufacturing line works by making changes to the line, the machinery used in the process, and fine-tuning other parts of the manufacturing process for improved productivity. For example, you can implement inventory tracking to allow for better control over production batches. Using lot numbers – or even serial numbers assigned to individual products – you can monitor the production line even more accurately. This implementation alone offers a long list of benefits, including the ability to do better quality control and recognize batches from which defective products originate.

Adding technology-based solutions to other parts of the manufacturing process helps too. Automation is another big leap you can make to further boost productivity and effectiveness, all while maximizing production efficiency on a whole new level. Using the lot numbers added earlier, you can automate things such as production quantity control, orders of raw materials, and delivery of finished goods to warehouses and retailers. Every part of the process is trackable and easier to manage.

Improve the People
The next part of the equation is the people running the manufacturing line. They are just as important as the machinery and software you use to improve efficiency. Workers who are concerned about productivity, the quality of their work, and the overall efficiency of the manufacturing line will perform better, even under the pressure of meeting customer demands. There is always a new and better technology on the market. It is up to the workers to maximize the new technologies added to the manufacturing line, and the only way they can fully utilize the new tools is through training programs and other personal development strategies. Even general courses in safety, management, and other subjects can help workers perform better as part of the manufacturing process.

Employee development is never a one-time thing. In order to have an effective development program, you need to design employee development as a continuous process. There are more things to do in this department too, including scheduling training sessions to minimize disruptions in the manufacturing process.

Invest in Collaboration
When you have multiple parts or sections in your manufacturing line, you must be familiar with how disruption in one section can put the entire line in jeopardy. There is actually a way around this risk. What you need is better collaboration between workers in the manufacturing line, particularly workers in different sections of the process.

Collaboration is something that can be built. To really boost productivity, workers must understand their roles and their importance to the whole process. Create a working environment that rewards good collaborations and you will see an immediate change across the line.

Don’t be surprised to find workers supporting others in meeting their manufacturing targets, even those who are in different sections. You can amplify the effects further by rotating workers and getting them familiar with other parts of the manufacturing process. Workers need to feel comfortable with the skills they have, as well as the fact that they are part of a bigger team.

Manage External Factors
There are a lot of external factors and risks to mitigate when running your own manufacturing line. These factors need to be managed as much as the internal factors we discussed earlier. Things such as the supply of raw materials and delivery of finished goods, the challenges lurking from outside the factory, and other risks faced by the manufacturing line are actually more manageable than you think.

When trying to use just-in-time supply to minimize inventory costs, for example, you can mitigate the risks of not having raw materials ready in time by doing better production forecasts and scheduling the line in a lean and efficient way. This can be done with the insights collected by the various IT solutions you use to monitor production, including the use of lot numbers and inventory tracking systems mentioned earlier.

The same can be said for accidents that happen outside of the factory. Let’s say a delivery truck carrying raw materials is involved in an accident; do you have a plan to mitigate this disruption? Work out scenarios that can potentially lower manufacturing productivity and formulate contingency plans for them. The more you prepare for these risks, the better you will be at handling them.

A better, more productive manufacturing process can be the key to capturing a larger market share, even in today’s competitive business landscape. With these five steps, improving your production line and achieving that high level of efficiency are certainly doable.

 







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