Manufacturing involves many complex processes and moving parts, both literally and figuratively. When large objects are produced in low volumes, manufacturers must streamline the processes whenever possible. Furthermore, they must regularly evaluate designs and regulatory requirements to maximize performance and optimize operational efficiency.
The manufacturer must support standardization, offer visibility into manufacturing information, and provide clients with product data. With so many tasks to handle, it’s no wonder many organizations struggle to simplify manufacturing processes. For example, a company cannot switch from lead screw manufacturing to precision ball screw manufacturing in a design without considering the far-reaching implications of this move. How can these processes be simplified today?
Organize the Workspace
Any clutter or disorganization on the manufacturing floor increases the time needed to complete tasks. In addition, it puts workers at higher risk of injury. Organize the floor to improve the flow of traffic as an item moves through the perforated metal panel manufacturing stage.
Ensure tools and materials are located where they are needed so employees don’t need to leave their stations to grab frequently used items. Consider the placement of equipment, and see if changes are needed to increase workflow efficiency. These simple steps will organize the workspace and increase worker satisfaction, as they won’t feel they spend a lot of time searching for things they need.
Coordination Among Various Departments
Employees on the manufacturing floor don’t work independently of other departments within the organization. Communication is critical among departments to ensure everyone is on the same page. This includes the manufacturing planning team, the shop-floor management team, and the workers on the production line.
Many companies choose to invest in software that allows them to handle everything from the initial planning and design stages to the distribution of the finished product and aftersales. With this program, all departments within the organization have one central location to share and gather information.
Put Skills to Use
Many manufacturers today choose to cross-train employees. Doing so allows them to move employees where they are needed at any given time to fill holes in the production process. However, they sacrifice efficiency when working to increase flexibility.
When workers are matched with positions that use their skill sets, they are more confident and will perform better. Mistakes are less frequent, and tasks take less time to complete. Workers are happier in positions where they are most proficient, and employers must keep this in mind and assign tasks based on each worker’s strengths.
Identify Weaknesses Across the Workforce
As an employer works to match employees with their strengths, weaknesses will come to light. To overcome these weaknesses, the employer should put training programs into place. These programs help boost efficiency by encouraging the use of best practices and standard operating procedures. Once an employee is properly trained, they know what the employer expects of them. This eliminates confusion and ensures there are no discrepancies that could make the manufacturing process inefficient.
Request Feedback from Employees
Who knows better how to streamline the manufacturing process than those actually doing the work? Meet with employees regularly to discuss what is working for them and where changes need to be made. Workers may also provide insight into potential solutions that will allow them to do their work more efficiently.
This feedback may be obtained in a variety of ways. Some business owners choose to send out surveys and allow employees to respond anonymously. However, if a viable solution is presented and the employer does not know who suggested it, they might not be able to follow through on the recommendation. Employers should consider this and discuss all possible ways to work with employees to gather feedback in a way that could lead to actionable steps.
Employees appreciate being asked for their feedback. Asking for feedback shows the employer values them and cares what they think. When employees are asked to be part of this process, they take more pride in their work, particularly when a suggestion they recommended is implemented. This benefits the company in the form of increased productivity and loyalty.
Process Evaluation
Falling into a rut is easy. People may often overlook things when they encounter them regularly. Think of the parent who suddenly notices their child has shot up an inch or two. They didn’t notice because it happened gradually. The same can be said of warehouse operations. Processes may grow inefficient without anyone realizing there is a problem.
Every manufacturer needs to continuously look for ways to improve operations. For example, making the move from lead screws to ball screws may offer numerous advantages. A company might overlook this one step because they have always used lead screws. It isn’t until the company begins falling behind competitors that someone realizes changes need to be made. Don’t make this mistake.
Evaluate all processes on a regular basis. Eliminate those steps that are no longer necessary or have no value. Find ways to simplify complicated processes and see where errors are commonly made. Look for solutions to eliminate these errors, again asking for recommendations from employees who use these processes regularly.
Consider Seeking Outside Help
If a manufacturer feels they still need help to simplify processes, look for outside help. Many consultants today work with manufacturers who find themselves in this situation. As they come into the organization with an objective eye, the consultants will spot problems that have been overlooked.
In addition, the consultants are familiar with the latest technology and tools. They can recommend items that may be beneficial to the manufacturer. While these consultants’ service includes fees, the insights they provide into daily operations are priceless, so this is one option every manufacturer should consider.
Simplifying and streamlining the manufacturing process won’t happen overnight. However, companies that commit to achieving this goal will find small changes add up to significant improvements over time. Bring all employees together and explain the benefits of undergoing this process. When everyone is committed, the process runs more smoothly. Begin simplifying the processes today for great results in little time.