Manufacturing is arguably one of the most inefficient areas of business. The fact remains that time is money, and if you are taking too much time to make your money, then chances are you are losing money.

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But how can you effectively improve efficiency without compromising on quality and productivity?

Workflow

You won’t know what can be modified until you understand how things work currently. There are three main areas you can break it down into to identify processes.

• People – Do you have the right people in the right positions with the right skills? Is there anyone in charge of keeping the vital route clear and on track? Are your goals well-defined, achievable, and safe?
• Processes – How long has it been since you set out your processes? Have you ever evaluated process improvement programs using value stream mapping? Where are the bottlenecks and pressure points?
• Technology – Is all of your technology and facilities in good working order? Is the technology you’re using right now for your needs? How simple is it to make output changes?

Understand how it works now before making any improvements. The adage “If it ain’t broke, don’t repair it” still holds. If you can’t justify the cost of new technology or equipment or the benefits do not exceed the cost of implementing it, it might not be worth the investment.

New Equipment and Technology

Once you’ve analyzed and mapped your current workflow, start looking for places where processes and/or technologies might be improved. Identify workarounds that may have been applied to processes that have been in place for a long time as new equipment was added or manufacturing methods changed.

Automation is a valuable method for increasing productivity and reducing errors.

Scheduling, inventory, and process monitoring will all benefit from new software solutions. Equipment upgrades such as a new shot blast cabinet will boost output speed and quality.

Consider the overall cost of ownership and how it will impact the bottom line when evaluating new technologies and equipment. If the overall cost of ownership is smaller than the technology or method you’re replacing, and it solves an issue like clearing a manufacturing bottleneck or reducing scrap, a high initial cost is justified.

Education and Training

Employee training and education should be an ongoing process. Certain forms of training, such as regular safety training for all workers wearing safety gear, are required in some industries.

To get the best out of new equipment and technologies, you’ll need to invest in preparation. Employee preparation is also a good retention strategy because new hires will need to learn the ropes, which slows down production.

• When new equipment is introduced, schedule training sessions for all operators.
• Maintain correct training records and, if necessary, schedule refresher sessions.
• Employees who want to advance or learn new skills should be given educational opportunities.

Ongoing education is vital to ensure you can maintain efficiencies in your workflow and reduce accidents, injuries, and downtime due to incorrect or poor training and knowledge.