3 Manufacturing Productivity Improvement Ideas Worth Your Time and Effort

OLEKSII KOVALENKO| August 27, 2019
3 MANUFACTURING PRODUCTIVITY IMPROVEMENT IDEAS WORTH YOUR TIME AND EFFORT
Without a doubt, the best manufacturing improvement idea generators are the people doing the work. Be it a manufacturing floor with complex equipment or a simple forklift route from production to a warehouse, employees are a business’s first line of defense against losses and inefficiencies.

Spotlight

Flowers Foods & Subsidiaries

Flowers Foods, Inc., with 2016 sales of $3.9 billion, is a leading producer and marketer of packaged bakery foods for retail and foodservice customers in the U.S. The company’s 47 highly efficient bakeries produce breads, buns, rolls, snack cakes, pastries, and tortillas. More than 85 percent of the U.S. population has access to the company’s fresh bakery foods through a network of independent distributors.

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How to Improve Production Scheduling: The 5 Crucial Elements

Article | December 8, 2021

The manufacturing production schedule is a critical aspect that enables the manufacturing business to complete each production activity precisely and on time. Allocating different raw materials, resources, or processes to distinct project phases is called a production schedule. Its goal is to make your manufacturing process as efficient and cost-effective as possible in terms of resources and labor — all while delivering products on schedule. As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity." – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca So, how is the overall production schedule managed? According to businesswire, the global APS (Advanced Production Planning and Scheduling) software market was valued at $1,491.22 million in 2020 and is anticipated to raise $2,941.27 million by 2028 expanding at an 8.86 percent CAGR from 2020 to 2028. Some software and tools are available to assist manufacturing organizations in properly scheduling production planning, including MaxScheduler, TACTIC, MRPeasy, and Gantt charts. Though there are numerous software programs available on the market for production scheduling, the most crucial aspect is determining which elements to consider when planning production. This blog will look at the five most important factors to consider while planning the production schedule. Five Elements to Consider When Scheduling Production As we saw in the introduction, production scheduling is used in the manufacturing process to assign plant and machinery resources, schedule human resources, plan production processes, and purchase materials. So, what are the primary components or stages of this production scheduling process? Let's take a quick look at each of them. Planning to Make the Best Use of the Company's Resources The role of planning in production scheduling is to use the company's resources to maintain a regular production flow. As a result, downtime is decreased, and bottlenecks are minimized, allowing production to be optimized. For production scheduling, two forms of planning can be used: Dynamic Planning: Dynamic planning is carried out under the idea that process stages will alter. So, materials must be ready, but production cannot begin until demand is decided. Static Planning: Static planning is done keeping in mind that all process steps will be completed on schedule and without adjustments. Routing to Determine the Order of Actions A “bill of materials” is used in discrete manufacturing to specify what things are needed and in what quantities. Routing determines the path and sequence of required phases of the process. It may involve in-house operations, but it may also comprise sub-contracted components that must be returned to the production flow for final assembly. Scheduling to Make Use of Predetermined Planning Levels To manufacture products from components or raw materials, scheduling makes use of the previously set planning level. As a result, it is time-dependent and must meet the demand outlined at the planning level. Each department, product, and procedure can have their own unique set of timetables. Sub-schedules for sub-assemblies or mixes and blends may be defined by department-specific master production schedules, utilized at the highest level to define product timeframes. Dispatching to Decide on Immediate Actions Dispatching assigns the following jobs to be done from a subset of the production queue. Dispatching is utilized to make quick decisions. This is in contrast to planning, which involves the planning of future actions. Dispatching is utilized in both pull and push production systems. Execution to Ensure that all Processes are Carried out Correctly Production scheduling must rely on proper execution to ensure that all processes are completed appropriately and in the sequence planned. It requires everyone to know what they are expected to do and when they are expected to do it. Execution requires knowledgeable management decisions, well-trained employees, correct data in the manufacturing plan and schedule, and consistent sales statistics and forecast numbers. All must be present for the organization to carry out its production plan and fulfill orders. How MRPeasy – A Production Scheduling Software Assist Manufacturing Companies in Scheduling Their Production? MRPeasy is a cloud-based material requirements planning (MRP) application explicitly designed for small manufacturing units. Its primary functions are purchase order management, forecasting, and inventory management. This software simplifies the process of scheduling production. It enables you to evaluate all of your anticipated manufacturing orders (MO). The bill of materials (BOM), purchasing, and stocking are all maintained in one location, allowing you to quickly book inventory and increase purchase orders (PO) for acquired parts. MRPeasy enables you to: Obtain all of the detailed information on all of your MOs Consider MOs as a single block or as distinct operations. Drag-and-drop operations and operations to reschedule Calendar or Gantt chart views are available for monitoring scheduled orders. Additionally, you can manage MOs smoothly. With the production planning component, you may create, amend, and update MOs. This app compiles an exhaustive list of all your MOs. You can track their progress based on the status of an order or a part's availability. Additionally, you can search for, filter, and export your MOs. Final Words How to schedule production for your organization requires extensive research, planning, and analysis of overall product demand as well as a grasp of the time required to meet the demand. Production scheduling techniques such as job-based planning, batch method, flow method, and others help develop a productive manufacturing production schedule. Include the elements mentioned above in your manufacturing scheduling to get the best possible benefits, such as better production efficiency, lower production costs, and on-time product delivery for your manufacturing in 2022. FAQ How production planning differ from production scheduler? Production planning and scheduling are often mixed. But there is a difference. Planning decides what and how much work must be done, whereas scheduling specifies who and when the work will be done. What is real-time manufacturing scheduling? Real-Time Scheduling is a production planning, scheduling, and tracking tool that enables manufacturing organizations to improve customer satisfaction and achieve optimal operational performance cost-effectively. How can scheduling be improved? Communication with staff is a great way to improve scheduling. This is true for all businesses, software or otherwise. However, management should not burden employees with ambiguous or unclear communication, and vice versa. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "How production planning differ from production scheduler?", "acceptedAnswer": { "@type": "Answer", "text": "Production planning and scheduling are often mixed. But there is a difference. Planning decides what and how much work must be done, whereas scheduling specifies who and when the work will be done." } },{ "@type": "Question", "name": "What is real-time manufacturing scheduling?", "acceptedAnswer": { "@type": "Answer", "text": "Real-Time Scheduling is a production planning, scheduling, and tracking tool that enables manufacturing organizations to improve customer satisfaction and achieve optimal operational performance cost-effectively." } },{ "@type": "Question", "name": "How can scheduling be improved?", "acceptedAnswer": { "@type": "Answer", "text": "Communication with staff is a great way to improve scheduling. This is true for all businesses, software or otherwise. However, management should not burden employees with ambiguous or unclear communication, and vice versa." } }] }

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Manufacturing in 2022 - Five Emerging Trends in the Industry

Article | October 8, 2021

The trends in the manufacturing industry for 2022 are expanding and altering the industry's conventional face. The future of manufacturing is going to merge with digitalization and technological applications. As a result, all operation methods, products, and manufacturing outcomes will be modernized with new technology applications. To brighten the future of manufacturing, manufacturing companies must examine new trends in the industry before developing their manufacturing plans for 2022. Technological advancements are the next game-changer in the manufacturing business. Adeaca's Vice President of Market Innovation and Project Business Evangelist had recently quoted in an interview with Media7 as, “As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity.” – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca The new trends in manufacturing are leveling up every part and element of the industry. In this article, we'll look at a new trend for each industry aspect that's assisting manufacturers in speeding up the production process, increasing ROI, and propelling their manufacturing business to new heights. Additionally, it will assist you in addressing current industry challenges such as forecasting product demand, addressing skilled manpower shortages, and increasing manufacturing plant efficiency. Five Manufacturing Industry Trends to Watch in 2022 Emerging trends in manufacturing provide a chance to review your production strategy for products and processes. Check out below the upcoming trends in manufacturing that are getting attention in the industry. Customer Engagement and Purchase Experience Creating an exceptional digital customer experience is a new trend in manufacturing. According to industry experts, mapping the customer journey and their interactions with your products is the first step towards establishing a positive connection with your potential consumers. A few of the most popular strategies to improve the consumer purchasing experience and engagement are as follows: Build a knowledge base for your products on your business website Create a comprehensive FAQs page that addresses all of the buyer's possible queries Create a chatbot to provide immediate help to the buyer with further inquiries Create a brand story and a comprehensive description of your manufacturing business If possible, provide product statistics and success stories, and content about consumer satisfaction with your product Create a product functionality video or explanatory picture material to familiarize the potential customer with your product These are some of the trends that engage your prospective buyers and increase their purchasing experience through a range of product-related information and educate them about you and your products. Smart Technology-enabled Products Smart is the new norm in every industry. The old operations and goods that were once a part of everyone's life have now been replaced by technology. Manufacturing is no exception to this alteration. Due to the increasing demand for smart products among customers, every company is now looking forward to inventing and manufacturing smart products. Explore and understand how you may incorporate cutting-edge technology (Artificial Intelligence, Machine Learning, Edge Computing, and Digital Twins, and more) into your products to help them stay updated with manufacturing trends. Virtual and Augmented Reality in Manufacturing (Industry 4.0) Transforming traditional manufacturing systems and processes into smart, tech-savvy ones is a new trend in manufacturing. The future of manufacturing is expected to witness this digitization in 2022 and beyond. Therefore, you must convert your conventional manufacturing plants into smart ones, i.e., as per the concept of Industry 4.0 – the fourth industrial revolution. Discover how prominent companies are implementing Industry 4.0 The following are some popular transformations that many popular manufacturing factories are adopting to become part of the industry revolution. To achieve a zero-carbon footprint, manufacturers may use analytics systems to determine the amount of trash they create and develop ways to eliminate it. (Implemented by Whirlpool) Utilize an analytics platform to decipher usage data for energy, water, and other utilities. (Implemented by Whirlpool) Utilize technology such as Siemens' Mindsphere, which enables online analysis of several aspects of a production plant and helps manufacturers create digital models using real-time data. (Implemented by Siemens) Utilize a combination of IoT and cloud-based technologies to avoid downtime and gather analytics data. (Implemented by Hirotec – a Japan based manufacturing company) Machine learning technology can be used to foretell and avoid system failures in your manufacturing plant. (Implemented by Hirotec – a Japan based manufacturing company) Utilize robotics and to accelerate manufacturing across many verticals. (Implemented by Ford) Utilize 3D printing to improve the precision of product design and to avert product defects during the early production stage. (Implemented by Aerospace: Airbus) These are some examples that other well-known manufacturing companies in the market, such as Hewlett-Packard, Ford, Whirlpool, and Siemens are currently using. So, consult an expert and determine how to leverage emerging technology to turn your production plant into a smart manufacturing unit. Internet of Things (IoT) to Boost Revenue Manufacturing companies have begun to leverage the Internet of Things to establish connectivity between machines and operational procedures throughout manufacturing. This linkage between machine and operation significantly decreases the human supervision required for each step and completely automates them. Manufacturers intend to incorporate these IoT trends in manufacturing into both their products and operational processes. IoT further enables manufacturers to operate and monitor their work remotely. As a result, they can concentrate on developing new strategies and preparing for future ventures. Shifting Focus from B2B to B2C Model Several manufacturers skip intermediaries and connect directly with their consumers to sell efficiently to their target consumer group. This purposeful approach has multiple benefits, which are outlined below. Manufacturers may skip the lengthy retail sales cycle and achieve a shorter time to market The absence of a third party between the manufacturer and the customer reduces the risk of brand misinterpretation or dilution Direct interaction with customers enables manufacturers to obtain more accurate consumer data, product feedback, and requirements for new product development Manufacturers can control the price of their products due to the absence of a third party between them and the target consumer group These benefits of the B2C model attract manufacturers and encourage them to develop added production techniques with these benefits in mind. Final Words Technology, innovation, and digitization are the future of manufacturing. The IoT trends in manufacturing are essential for industrial production and will allow the manufacturing industry to obtain a new competitive edge. Hence, manufacturers must keep in mind this industry revolution (industry 4.0 and 5.0) while developing strategies for their manufacturing operations in 2022. FAQs What are the benefits of adopting the Internet of Things in manufacturing? IoT devices can monitor industrial operations, manufacturing cycles, and other warehouse data management processes automatically. This benefit decreases the amount of time spent monitoring individual operations and increases production speed. What role will smart manufacturing play in the future? According to a grand view research analysis, the smart manufacturing market was worth USD 236.12 billion in 2020 and is expected to extend at a 12.4 percent compound annual growth rate to reach USD 589.98 billion by 2028. What are the critical components of the smart factory of the future? Robotics, the Internet of Things, big data, and cloud-based administration will be critical components of the future smart factory.

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How Can Manufacturers Redefine Marketing Strategies in the Age of COVID?

Article | April 27, 2021

What do you need to create a killer B2B marketing plan or scale it to support a new marketing business in the age of COVID-19? Many manufacturing companies struggled when the coronavirus started. Some of them paused all marketing activities, waited for the lockdown to end, and then made up for potential losses. Looking at this situation, where does your business stand when it comes to marketing planning in 2021? Simply copying and pasting the old calendar, changing dates and campaign names will be far from being sufficient for the years ahead. Instead, establishing steady and tangible SMART B2B manufacturing marketing goals, which are specific, measurable, relevant, time-bound, and flexible, is crucial for marketers. And such goals should be made every quarter and bucketed under a planned manufacturing marketing strategy. Aren't you sure what to include in your B2B manufacturing marketing plan? Read on the following ideas that will help you do marketing in the age of COVID-19. Redefine your Budget Season As marketers in industrial manufacturing face planning failures such as inevitable spreadsheets, board meetings, sales, and client handling that accompany for an entire year, they're also facing dwindling budgets. So, redefining your manufacturing marketing budget in 2021 will be one of the most important aspects of marketing for manufacturers. Digital Marketing AMA's latest CMO Survey found that manufacturing marketers anticipate an 8.4% rise in digital marketing spending throughout 2021. What is your digital marketing goal in 2021? Generate double-digit leads for products and services? Promote or launch a new product or service? Expanding reach by ranking in Google's first search engine result page (SERP)? Creating a proper digital marketing plan will leverage to know beyond its tip of the ice. The digital platform will keep your marketing activities on track and in one place, and you will see what's working and what doesn't. This way, you can create a solid budget to implement digital marketing in your marketing business. Customer Experience A survey found that customer experience expenditure surged 10% from past years after companies started marketing budgeting. This prominently included A CRM (customer relationship management) platform. So, including a CRM will benefit your business to track and manage contacts present in your marketing pipeline. Social Media Platforms Interestingly, social media expenditure has soared by 74% since February 2021, and the investment by other manufacturers has paid off. Manufacturers report that social media has contributed to the company's performance 24% more after the pandemic. In general, 62% of marketers report that the importance of social media marketing for manufacturing has grown during the pandemic due to its critical role in reaching customers digitally. It's clear that companies that already implemented digital marketing see the value of budgeting for social media, which increased the positive results of marketing. So, when you set up a new budget, include social media to grow your business. 5 Things to Consider while Marketing your Business A Lead Scoring Model One of the most important aspects of marketing in manufacturing is implementing a lead scoring model. Investing in it will allow you to see through the valuable metric of your leads that will make you determine which ones are qualified. Metrics include your ideal customer's demographics such as company size, revenue, industry, and main pain points. Also, these have a number of website visits, specific page views, content downloads, contact forms, emails unlocked, engagement with social posts, and more. Regularly evaluate your lead scoring model and update to ensure your metrics are closely related to your ideal prospect. It would lead both sales and marketing for manufacturers to identify valuable leads in your database easily. Invest in A Video Marketing Strategy Video Marketing is a great deal. As per Cisco's research, by 2021, videos will account for 80% of all internet traffic. In addition, being one of the internet’s traffic sources, it’s practical and reasonable. Video marketing for manufacturers has been profitable by 83%. From creating more leads per year to a rise in sales, 80% say that video marketing has aided their business significantly. If you haven't invested in video marketing yet, or if you've only dipped your toes in the water, 2021 is the year to dive in completely. As per HubSpot's 2020 State of Marketing report, video beats content forms like blogging, email, and infographics. Also, video is the most-used marketing content type for manufacturers. So, there are many tools and resources that make it easy to get started with video marketing. Videos help to sell industrial manufacturing products and create a brand story. So, think about it and include this when budgeting your marketing plan. Move Beyond Basic Marketing Analytics Through digital marketing, manufacturing marketers have been trying to determine the ROI of their efforts. But do you know that most of them have been doing a lousy job? That's because they, and the tools they use, tend to focus on things that don't matter. These include views, clicks, etc. More than 600 manufacturers and industrial companies in the U.S. have learned that their marketing and sales are going wrong. Out of which, 35% of manufacturers are not using an analytics tool like Google Analytics. So, it is advisable to move beyond basic marketing analytics to track how much traffic is coming to your website. The latest tools can identify companies visiting and allow salespeople to engage them in their research phase. It will result in creating and maintaining promising relationships with clients. Content Isn't Optional A rock-hard content marketing plan is the core of your online business's success. Keep in mind; a few blogs are not sufficient to get accurate results! Creating content helps (by answering) your potential buyer's queries in their research process and throughout their buying journey. A survey found an online search or a blog acts as a key source for finding answers to questions. As most sales are happening online now, Hubspot suggests that manufacturing businesses' sales will surge incredibly in 2021. An average B2B manufacturing marketing has involved 68% of stakeholders. Prospects are now making more decisions by reaching out to a company than ever before because they want your website and social channels to educate them completely. If they can't find the information on your owned channels, they might turn to your competitor's website instead. This makes content the most important aspect of marketing. When it comes to steady and consistent lead generation for b2b manufacturers, content is at the front and center of all the B2B manufacturing marketing trends. So, take content seriously instead of keeping it just as an alternative. What's Important for 2021? Plan in quarters Many companies create full-year planning calendars in November and December. The pandemic in 2020 has taught us that to plan too ahead in advance can get your business to flow in the wrong direction. Because who knows whether those plans or events would fall digitally or be back to in-person. Will your target audience be as approachable as to emails and webinars or not? So, plan your marketing things quarterly from annual to ensure your business leads in the right way. Audit Constantly It's not advisable to keep an eye on one particular marketing metric, for example, tracking traffic to your website. Instead, it's the whole picture that matters. 2021 is the year to evaluate every goal, every channel, and every message related to your business. With this, think about creating a big picture as well—company positioning and values, competitive research, and even business goals. Here are some standard audit actions recommended: 1. Conversion rates Visitors converting to leads Leads converting to customers 2. Email engagement Number of sent emails Deliverability metrics Subscriptions/unsubscribing 3. Revenue attribution audits How much revenue can be credited to marketing campaigns? 4. Campaign success How did all of the individual elements of your campaign perform? That includes: The site and landing pages Email marketing Paid ads and PPC Social messages How did the campaign perform against other campaigns? 5. Social media audit Engagement by channel Overall reach and growth 6. Funnel audit How effectively contacts are moving through the funnel In addition, conduct an audit and analysis vertical to ensure all the automation is taking place or running appropriately. Doing it will help your marketing team keep a constant check on all the processes and cater to you with exact marketing activities. Keep this activity active throughout the year. Continue Shifting Budgets—Don't Be Afraid Much of 2020 has been experimental in marketing for manufacturers. Many manufacturing companies moved away from in-person events to a webinar, shifted expensive prospect meetings to internet meetings, trade events to PPC, website, and content creation. In these cases, you might have to shift your budgeting when needed. Consider revising the budget to create advertorials, creative virtual events, and strategic lead generation tools if you plan in quarters. Along with these, 2021 brought a good time to invest even in intent data, ABM, SEO, and other automated technologically advanced digital initiatives. According to a recent study, manufacturing companies are now 21% more likely to invest in automation and technology. As they are now inclined towards the use of webinars & virtual events (20%), search & social media (14%), and website (12%). All of these increased in light of COVID-19. So, start planning for what's sure to have a better year ahead with your marketing strategies. Frequently Asked Questions What is the role of marketing in the manufacturing industry? Marketing plays a pivotal role in the manufacturing industry. Through marketing, customers are well informed about products or services a company offers. Also, marketing helps in building the brand name, awareness, and visibility of a company. How to use social media marketing in manufacturing? Social media marketing in manufacturing can be ideally used in these ways: Choose right platform Share useful content Create advertisements Create creative posts Connect with in-market participants Encourage engagement Create videos and share Address problems and provide solutions through content What are the important aspects of marketing for the manufacturing industry? Being the crucial part of any company in the manufacturing industry, essential aspects of marketing are: Website Brand name Platform Promotion SEO Sales How can Email Marketing help to market in the manufacturing industry? Email marketing in the manufacturing industry can help by creating informational content. Start from offering subscription options to potential customers, clients, and visitors. Send updates, information, an overview of the company's services and products to aware the reader and convert them into loyal customers. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "WHAT IS THE ROLE OF MARKETING IN THE MANUFACTURING INDUSTRY?", "acceptedAnswer": { "@type": "Answer", "text": "Marketing plays a pivotal role in the manufacturing industry. Through marketing, customers are well informed about products or services a company offers. Also, marketing helps in building the brand name, awareness, and visibility of a company." } },{ "@type": "Question", "name": "HOW TO USE SOCIAL MEDIA MARKETING IN MANUFACTURING?", "acceptedAnswer": { "@type": "Answer", "text": "Social media marketing in manufacturing can be ideally used in these ways: Choose right platform Share useful content Create advertisements Create creative posts Connect with in-market participants Encourage engagement Create videos and share Address problems and provide solutions through content" } },{ "@type": "Question", "name": "WHAT ARE THE IMPORTANT ASPECTS OF MARKETING FOR THE MANUFACTURING INDUSTRY?", "acceptedAnswer": { "@type": "Answer", "text": "Being the crucial part of any company in the manufacturing industry, essential aspects of marketing are: Website Brand name Platform Promotion SEO Sales" } },{ "@type": "Question", "name": "HOW CAN EMAIL MARKETING HELP TO MARKET IN THE MANUFACTURING INDUSTRY?", "acceptedAnswer": { "@type": "Answer", "text": "Email marketing in the manufacturing industry can help by creating informational content. Start from offering subscription options to potential customers, clients, and visitors. Send updates, information, an overview of the company's services and products to aware the reader and convert them into loyal customers." } }] }

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Lessons Learned in Electronics Transforms Other Discrete Manufacturing Operations

Article | May 10, 2021

Jason Spera, picture left, recently shared his vantage of the changes for factory floor automation in 2021. Jason is CEO and Co-Founder, Aegis Software. Spera is a leader in MES/MOM software platforms for discrete manufacturers with particular expertise in electronics manufacturing. Founded in 1997, today more than 2,200 factory sites worldwide use some form of Aegis software to improve productivity and quality while meeting regulatory, compliance and traceability challenges. Spera's background as a manufacturing engineer in an electronics manufacturing company and the needs he saw in that role led to the creation of the original software products and continue to inform the vision that drives Aegis solutions, like FactoryLogix. He regularly speaks on topics surrounding factory digitization, IIoT, and Industry 4.0. Contact Jason on LinkedIn.

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Spotlight

Flowers Foods & Subsidiaries

Flowers Foods, Inc., with 2016 sales of $3.9 billion, is a leading producer and marketer of packaged bakery foods for retail and foodservice customers in the U.S. The company’s 47 highly efficient bakeries produce breads, buns, rolls, snack cakes, pastries, and tortillas. More than 85 percent of the U.S. population has access to the company’s fresh bakery foods through a network of independent distributors.

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