Productivity is the measure of how much output a worker produces in a given amount of time. The more productive a worker is, the more they can produce in a shift, and the more efficient the factory as a whole becomes.
There are many things that can slow the production process in manufacturing, and it’s critical to avoid them if you want to be productive. Here are the top 10:
1. Lack of Standardization
When different parts are made by different people and to various specifications, it can be difficult to achieve consistent quality. This can lead to defects and rework, which lower productivity. A lack of standardization can also make it difficult to automate manufacturing processes and to track inventory.
– To avoid this pitfall, develop standardized processes and specifications, and make sure that everyone on the production floor understands and follows them.
2. Lack of Training and Knowledge
If employees don’t have the training and knowledge to do their jobs properly, it can lead to defects and wasted time and money. This is especially true when new systems and software are integrated into your operations and training may need to be updated.
– To avoid this, make sure that everyone who works in the plant is properly trained and has the knowledge they need to do their jobs effectively. When changes are introduced to your processes, provide updated training.
3. Defective Parts
Defective parts can cause a number of problems in a manufacturing plant, including rework, scrapped product, and downtime. All of these reduce productivity and profitability.
– To avoid defective parts issues, make sure that quality control is a top priority in the plant, and invest in quality assurance measures such as good manufacturing practices (GMP) and statistical process control (SPC).
4. Poor Quality Control
As mentioned, defective parts can come as a result of poor quality control. Poor quality control can also lead to customer complaints and loss of business.
– To avoid quality control issues, implement manufacturing technology that can improve quality control through automation. Robust quality control systems can help avoid loss of scrapped products and valuable customers.
5. Poor Equipment Maintenance
If your equipment is not properly maintained, it can lead to unnecessary downtime. Equipment and software not only needs to be updated regularly, it also needs to be: protected from cybersecurity incidents; seamlessly integrated with your other software and hardware systems; and replaced when necessary.
– To avoid this pitfall, make sure that the equipment is kept up to date. Keep track of all your devices and which users are authorized to use it. Hire a manufacturing technology expert to make sure your systems are properly integrated and protected.
8. Poor Inventory Management
In a manufacturing plant, inventory can take up a lot of space, searching through inventory can take up a lot of time, and it can be easy to lose track of what you have. This can result in wasted time and money looking for parts that are not in stock and having to order them using costly rush shipping methods from suppliers.
– To avoid inventory issues, develop and implement an effective system for tracking inventory and make sure that everyone on the production floor is aware of it. Keep a close eye on inventory levels and reorder parts only when necessary.
9. Lack of Standardized Packaging
Lack of standardized packaging can cause major confusion in the warehouse and on the production line. When packaging isn’t consistent, products can get mixed up, messed up, and improperly sent to clients.
– To avoid this issue, create consistent packaging guidelines across all departments. Ensure your employees understand what the packaging labels mean and the issues that come from improper packaging.
10. Lack of Communication and Collaboration
Poor communication across your production plant can lead to major issues. For example, if marketing sends out specifications for mass customization without coordinating with production, it can cause delays in getting the product to market.
– To avoid communication issues, Encourage communication and collaboration between departments.Make sure that everyone in the company can be notified in real-time of changes that need to be made or updates that need to occur, as well as how their department contributes to it.IMplementing technology such as Andon systems can notify you as soon as there is a problem or disruption on the production floor.
In order to ensure that your manufacturing plant is productive, it’s important to avoid these common issues that manufacturing facilities are often faced with.. By implementing the right measures and systems, you can keep your plant running smoothly and increase productivity.