According to the old saying that time is money. The more output you can get within a short period and the higher your earnings get you think? If you’re struggling to improve your production or when everything seems to be going well there are many ways to boost your production without sacrificing quality. These include removing obstacles to restructuring the way you work.
Here are six strategies to boost productivity in your manufacturing plant.
#1 – Go Over Your Workflow
It is difficult to know what needs to be altered until you understand the way things work today. Three areas of the system contain crucial details that will help you determine necessary adjustments.
- People Do you have the right people who have the appropriate capabilities in the right areas? Have you got a dedicated project manager who can ensure that the crucial path is clear and on the right track? Are the objectives clearly stated real, achievable, and safe?
- Processes What was the most recent time that you recorded your processes? Have you ever used value stream mapping to evaluate the effectiveness of your process improvement initiatives? What are the areas of pain and bottlenecks?
- Technology and equipment Are all of devices in great condition? Do you have the latest technology that you depend on the best to meet your current requirements? What is the process to change production?
Before making any changes, be aware of how things operate in the present. There’s still a lot of value in the old saying, “If it ain’t broke then don’t repair it.” If you cannot find a safety or financial reason to change take a long, hard look about the importance of the outcome you expect to achieve.
#2 Update Processes and Technology
After having looked over and sketched out your current workflow, begin identifying areas where your processes or technologies could benefit from changes or updates. Methods which have been in operation for quite a while may be plagued by workarounds since new equipment was introduced or manufacturing methods were changed.
- Automation is an effective instrument for increasing efficiency and decreasing errors.
- The latest software options can help in scheduling, inventory or monitoring work flow.
- The improvements in equipment can increase the speed of production and also quality.
When looking for new technologies and equipment, bear in your mind the cost of ownership as well as how your bottom line will be affected. The initial expense can be worthwhile if the overall cost is less than the process or technology you’re replacing, and if it can solve a problem like removing production bottleneck, or reduces scrap.
#3 – Make a commitment to scheduled maintenance
The fastest method of slowing things down is to not pay attention to regular maintenance. Maintenance downtime is much less than downtime caused by damaged and worn-out equipment. Maintenance can be scheduled, breaks always occur at the worst time.
- Instruct all operators in regular maintenance and troubleshooting techniques.
- Make sure to schedule preventive maintenance at regular intervals.
- Determine the ideal time to maintain your equipment using data from the floor and workflow procedures.
- Don’t delay maintenance.
Regular maintenance will ensure that your equipment will continue to function smoothly, without sudden interruptions or stoppages in work.
#4 – Learn and train employees
Training and education of employees is a continuous process that continues to be ongoing. In certain sectors, certain kinds of training are required for employees, like regular training on safety for all employees wearing safety equipment. Technology and equipment that is new require training in order to gain the best worth. Education for employees is an effective way to retain employees as new employees require time to get their skills up and running and can lead to a decrease in production.
- Plan the training of all employees after new equipment is put in place.
- Keep track of your training and refresher schedules if required.
- Provide educational opportunities to employees who want to grow or acquire new skills.
Don’t restrict education and training to the use of equipment. Your manufacturing plant will run more smoothly if everyone is aware of your workplace harassment policies and appropriate communication.
#5 – Organise the Workspace
Eliminating clutter and movement saves time.
- Reducing movement for maximum performance of the task.
- Find the most efficient design of the tools and materials to complete the task.
- Take out any tools that are not needed or used and equipment from the workspace.
- Organise your storage space to cut down on time needed to locate documents, materials, and equipment.
- Layout the manufacturing floor in order to increase efficiency.
Reduce the amount of travel time and distance as much as is it is. If a product has to be transported from one machine to the next Is there a way to decrease the distance, align the item, or move the item faster and secure to the next stage during the process? Are there software solutions which could help with the process of scheduling?
Inexpensive movement is an indication of poor organization , and could cause a lot of damage in terms of production time. Look into techniques like Kanban (just-in-time manufacturing) to cut down on the amount of delays and boost efficiency.
#6 – Maintain Optimal Inventory
If you’re in possession of a large inventory, you’ll require a space to store it . You can also hope that you’ll make use of the entire amount. If you’re not able to use all of it there is the chance of a shutdown as you wait for additional inventory. It is crucial to optimize inventory in the case of the principles of lean manufacturing, such as that previously discussed Kanban method.
- Make use of software to track the inventory and send out automatic notifications of any shortages. You might be able to give vendors direct entry to the inventory numbers and automate the fulfillment of needed items.
- Establish preferred vendor relationships to be accountable in the high-quality of components and the timeliness of delivery.
- Make forecasts about the effects of particular shortages , and then put procedures in place to prevent production delays.
Track rejection rates as well as quality declines and late delivery dates so you can correct these issues with your vendor or search for a replacement one. If you are aware that one of your suppliers is experiencing major changes, such as selling to a different company or a merger, ask for assurances and assurances that your delivery schedule will be the same exactly as they were before.
Productivity growth is best achieved through intentional change instead of fast “fixes” which may be beneficial in the short-term but can cause problems for the long term. Additionally an increase in productivity on the backs of employees could cause burnout and turnover, as in addition to costly safety issues.
A thorough examination of the current processes and equipment may reveal problems that can be easily addressed with changes to the procedure or new technology. Inspecting and maintaining equipment can prevent sudden work interruptions. Training and a well-organized workplace can ensure a safe workplace and can lead to new ideas from workers themselves on solutions for the problems they face daily.
In the end, higher productivity can lead to higher revenues and also the chance to grow your business, accept more tasks, or raise the pay of employees or buy new equipment. It is a good idea to examine your procedures regularly. The latest production equipment, materials, and methods are available every day. Make sure you are ready to implement techniques that can provide the highest benefit to your business.