Article | February 25, 2022
Improving manufacturing efficiency and enhancing business revenue is the ultimate goal of every manufacturing business. Effective manufacturing process management may help businesses grow and discover innovative manufacturing processes. Facts and data fill the days of plant managers and engineers. However, it appears that many firms are still unable to devise a strategy for resolving long-standing challenges in their organizations.
“If you define the problem correctly, you almost have the solution.”
– Steve Jobs
In this article, we will see the five ultimate ways of manufacturing flow management. Additionally, we will also see three industry leaders' examples and understand their processes for production management. So, let’s get started first with tips to improve production efficiency.
Five Ways to Improve Production Efficiency
Recognize and Eliminate Waste
Waste is a cost that should be minimized in the manufacturing business. Additionally, waste is a broad term in this industry since it involves labor hours, energy use, and material consumption, to name a few. However, material waste is typically the most significant worry in the industrial business. When looking for strategies to decrease waste, you must rely on the results drawn during the evaluation of your manufacturing line.
When identifying waste, keep in mind that each operation on your production line generates some trash; finding the procedures that generate the most waste is the most effective strategy to minimize total waste. However, you may reduce trash by recycling or reusing garbage rather than discarding it. If you are unable to eliminate the majority of your garbage, you should consider selling it to a company that can properly dispose of it.
Evaluate the Production Process
In a manufacturing business, the production line is at the heart of how the business operates, and hence, production line efficiency improvement is critical. When reviewing the production line, one must also consider the often overlooked elements, for example, the loading dock bumper and other necessary loading dock equipment. While sourcing and maintaining loading dock bumpers, you can rely on top industry service and equipment suppliers.
This will guarantee that your production line is equipped with everything it needs to operate properly. Another critical statistic to examine is throughput. This metric is used to determine the average number of units produced within a specified period. You must have high-quality equipment to ensure that your production line runs smoothly. Analyzing throughput can help spot difficulties in the production line when throughput is not quite up to pace.
Another aspect of production line efficiency improvement is capacity utilization, which determines your factory's overall output capacity. This enables you to monitor the functioning of your production line at all times.
Determine Bottlenecks
While discovering any flaws in your manufacturing line, you will unintentionally locate your production's major bottlenecks. Bottlenecks are breaks in your manufacturing line, supply chain, or any other business activity that obstruct the performance of another operation.
For instance, a certain machine may require repair at a plant, necessitating a half-day shutdown.
Any procedure that needs the operation of that particular machine is subsequently rendered inoperable. That machine becomes the bottleneck at that point. There are other types of blockages. Another instance is when an administrator who is required for approval falls ill.
Once you've identified your most frequent bottlenecks, you may work on reducing them and increasing productivity by decreasing bottleneck-related downtime.
Enhance Training Practices
The way your workers work ultimately impacts the productivity of your entire organization. Lack of training equates to inefficiency, and vice versa. To achieve optimal employee performance, each team member must be empowered throughout the production process. This isn't as simple as writing a pamphlet from which someone can be taught. Highly effective workers need to be taught on the job by someone who is watching them.
However, you must first establish uniform standards throughout your organization, starting from the top. This approach will help your employees understand that they will get organized or informal training to upgrade the skills and knowledge necessary to work successfully during the change's implementation. Training may take the form of a series of online microlearning modules or a blended learning method that includes face-to-face training sessions as well as on-the-job coaching and mentoring.
In addition, PWC is of the opinion that workers should ask the following questions to help them be more efficient in the long run:
Is what I’m doing now adding value, or am I just doing it because this is the way I’m supposed to do it?
If I were the customer, would I pay money for the activities that I was engaged in?
Allow your staff to generate suggestions for efficiency improvements on their own. After all, no one knows their operations better than they do.
Calculate and Organize Your Workspace
You can optimize production efficiency if your staff can perform their duties in a well-organized work environment. Hence, it is critical to prioritize measuring and organizing the workplace. It is critical to quantify each aspect of your business first, as this will provide you with a clear picture of what works and what does not. After that, you'll need to make sure that everything in the office is in order so that your employees can work efficiently.
Three Companies That Redefined The Innovative Manufacturing Processes
Ford
Henry Ford delivered to the world far more than simple automobiles. His company was the first to integrate a full production line process, paving the way for contemporary mass manufacturing. He devised a moving conveyer belt assembly line, which represented a radical departure from traditional industrial procedures. While his production procedures were restricted by current standards—they only allowed for limited customization—he laid the groundwork for modern manufacturing and a new way of thinking about processes.
Toyota
The Toyota Production System illustrates a deeply embedded cultural and managerial concept. This concept emphasizes the continuous improvement of work processes and systems. This approach focuses on identifying and resolving issues and ensures that every business action adds value to consumers. Dr. W. Edwards Deming and writers James Womack, Daniel Roos, and Daniel Jones brought it to the American public’s attention in the 1980s and 1990s (in "The Machine that Changed the World"). It was, and still is, a radically different management style for the great majority of organizations. Most people are familiar with Toyota Production System tenets like "just in time."
GE
Under former CEO Jack Welch, GE promoted the use of Six Sigma in business operations and provided a blueprint for adoption in the corporate setting that practically everyone sought to copy (at least for a while). Welch made Six Sigma training a pre-requisite for every employee who aspires to higher levels of leadership inside the business, and he enforced its implementation at all levels. The "GE Workout" is an extremely concentrated session (typically over many consecutive days) that evaluates business difficulties and suggests solutions. GE created it as a spin on the Six Sigma toolbox.
Final Words
To accelerate the overall growth of your manufacturing business, you must have innovative manufacturing processes that help improve manufacturing efficiency. You may consider the above mentioned ways to improve production efficiency and get the most out of your production set up. Giving employees new tools is probably the quickest method for managers to change a production process. Moving ahead, finding factory-direct manufacturers that can deal with each company's unique circumstances is also encouraged. Identify and avoid problems so you can then look at current data and waste to develop new and better ways of doing things.
FAQ
What is manufacturing efficiency?
Manufacturing efficiency aims to make products at the lowest feasible overall cost. It's all about maximizing the use of limited resources while minimizing the waste of time, materials, and energy.
What is a manufacturing process flow system?
The manufacturing process flow system shows the granular activity-level stages that must be completed to manufacture finished items from the moment raw materials are delivered to the manufacturing facility until they are transformed into finished goods.
What are the four manufacturing components?
Below are the four components of manufacturing:
Production equipment as well as tools, fixtures, and other relevant hardware.
A material handling system.
A computer system to coordinate and/or control the preceding components.
Human personnel to run and manage the system.
Read More
Article | December 30, 2021
Risk management in manufacturing has always been a top priority for manufacturers to avoid any unfortunate incidents. As a result, it is possible to create a more secure work environment for employees by conducting risk assessments and implementing remedies.
“If you don’t invest in risk management, it doesn’t matter what business you’re in, it’s a risky business.”
– Gary Cohn, an American Business Leader.
As of 2019, the worldwide risk management market was valued at $7.39 billion, and it is expected to rise at a CAGR of 18.7% from 2020 to 2027, according to allied market research.
Why is Risk Assessment Critical in Manufacturing?
The manufacturing industry must have a credible risk assessment and management plan to defend itself from any breaches. Risk assessment helps firms understand the dangers they face and their implications if their systems are compromised. Hence, risk assessment is very critical in the manufacturing industry.
Five Risk Assessment Principles
Identify hazards/risks - Employers must examine their workers' health and safety risks. Therefore, an organization must regularly inspect its employee’s physical, mental, chemical, and biological threats.
Identify who may be hurt and in what way – Identifying the personnel both full-time and part-time at-risk. Employers must also examine threats to agency and contract personnel, visitors, clients, and other visitors.
Assess the risks and act accordingly - Employers must assess the likelihood of each danger causing injury. This will evaluate and lower the chance at the working space. Even with all safeguards, there is always some danger. Therefore, employers must assess if danger is still high, medium, or low risk.
Get the Risks Documented - Employers with five or more employees must record the critical findings of the risk assessment in writing. In addition, register any risks identified in the risk assessment and actions to minimize or eliminate risk.
This document confirms the evaluation and is used to examine working practices afterward. The risk assessment is a draft. It should be readable. It shouldn't be hidden away. The risk assessment must account for changes in working techniques, new machinery, or higher work objectives.
5 Manufacturing Risks to Consider in 2022
Accidents at Work
Even if official safety policies and programs are designed, followed, and enhanced, manufacturers may endure workplace accidents and injuries. Risk assessment for workplace accidents assists in mitigating the negative impact on both employees and the organization.
Environmental Mishaps
Manufacturers have distinct issues regarding fuel handling and hazardous waste disposal in facilities. Sudden leaks or spills may be extremely costly to clean up and result in fines from state and federal agencies. Risk assessments for such plant accidents assist businesses in mitigating financial losses.
Equipment Breakdowns
Essential machinery throughout the production process might fail at any time, incurring significant repair or replacement costs. Therefore, it's critical to recognize that business property insurance may not cover mechanical issues.
Risk assessment and prepayment solutions protect against equipment failures without interfering with typical company operations.
Supply Chain Disruption
Dependence on your supply chain may result in unintended consequences that are beyond your control. For example, if you experience downtime on the manufacturing line due to a supplier's failure to supply materials or parts, you risk losing revenue and profitability. If a disturbance to your supply chain poses a hazard, risk management can assist you in managing it more effectively by quickly identifying the risk and providing a suitable response.
Operation Temporarily Suspended
Depending on the severity of the weather event, a factory might be severely damaged or perhaps utterly wrecked. While major repairs or rebuilding are being undertaken, recouping lost income might be vital to the business's future profitability.
Risk assessment in this area enables your organization to budget for overhead expenditures such as rent, payroll, and tax responsibilities during the period of suspension of operations.
Final Words
Risk management is critical in manufacturing because it enables manufacturers to comprehend and anticipate scenarios and create a well-planned response that avoids unnecessary overhead costs or delays in delivering the production cycle's final result. Manufacturing risks are undoubtedly not limited to the risks listed above and may vary according to the nature of the business and regional environmental conditions. Therefore, create a well-defined strategy to overcome threats in your business and be productive at all times.
FAQ
How are manufacturing business risks classified?
In most cases, the business risk may be categorized into four types: strategic risk, regulatory compliance risks, operational compliance risks, and reputational risks.
Why should a manufacturer conduct a risk assessment?
Every manufacturing employment has risks for injury or illness. But risk evaluations can significantly minimize workplace injuries and illnesses. In addition, they assist companies in discovering strategies to reduce health and safety risks and enhance knowledge about dangers.
Read More
Article | January 19, 2022
Manufacturing branding is a relatively recent trend that is gaining traction in the manufacturing sector. Brand marketing is important for manufacturers in a variety of ways, including increasing business revenue and establishing product credibility within their target consumer group.
82% of people feel better about a brand after reading personalized content.
94% of customers are inclined to develop a relationship with a brand that is completely transparent.
13% of consumers would spend 31-50% more on your products or services if they believed your business was making a positive difference in the world.
In this article, we will look at the advantages of branding to a manufacturer as well as how brand manufacturing may be established.
What Difference Can Manufacturer Branding Make?
"A brand is a voice, and a product is a souvenir"
-Lisa Gansky, an American entrepreneur, writer, and speaker
Your Name and Work Will Be Publicized
Branding is the process of enriching your products with a visual, linguistic, and conceptual identity that differentiates them from competitors. Ideally, factory branding would help you reach out to your potential clients by making them aware of your company's name and becoming familiar with what you do.
Brand Marketing Builds Emotional Bonds
Manufacturing branding is more than merely developing an image in the minds of your customers. It's about telling a story that strikes a chord with them.Once you've defined your message and the motivation for developing your products, customers will be able to connect with you more easily.Relatability is critical in an era of ever-changing trends and consumer behavior. Your clients will simply switch over to another firm that provides the same service and fosters a sense of belonging. The emotional value of your manufacturing brands should not be underestimated.
Building Trust Is Easier with a Strong Brand
A manufacturing brand that wishes to remain in business for the long run will communicate with its customers. The customers understand that you would not connect or share your story unless you intended to grow with them. However, this strategy works only if the factory branding is well-executed and demonstrates its authenticity. Modern customers can easily notice dishonesty or the use of a phony character.
Increase of Distribution Channels
Working on your manufacturing branding will help you expand your sales. Just make sure you have the necessary tools to sell via different channels. Creating a memorable brand doesn't merely attract customers. It will also assist in attracting potential distributors who may otherwise be reluctant to be your distributing partners. Your ability to negotiate quality agreements with resellers and reps will increase when your manufacturing brand is well-known. It simplifies their lives and saves them money on marketing.
This is a domino effect issue. More distributors mean more exposure for your business, but a delicate balance must be maintained. Your personal connection with clients may be lost if you abdicate brand responsibility. So, provide superior customer service to maintain a connection with your customers.
Profit Margin Is Increased
A strong manufacturing brand will allow you to sell at greater prices. People will be happy to pay for a quality brand that they can trust. But what would really set you apart from the rest is if you could beat private companies at branding. Private brands are the house brands of shops and huge resellers who offer cheaper copies of your goods. Customers should be able to tell the price difference between a factory brand and a private brand.
"You can’t build a reputation on what you are going to do."
– Henry Ford, the founder of the Ford Motor Company
How to Build an Effective Manufacturing Brand?
Identify Your Intended Audience
Identifying your target demographic is the first step in intentionally building your brand. You can build a buyer persona of the typical user of your product or by analyzing your current consumer base. Consider their age, gender, industry, occupation, education, interests, etc. To grow your brand and market your products more effectively, you need to create a buyer persona.
Conduct Competitor Analysis
Following that, it would be advisable to analyze your competitors' brands. In various markets and with companies in general, there are many brand features that are unique and widely utilized, and it would be counterproductive for a corporation to highlight those elements. For example, many B2B companies take pride in their product quality, reliability factor, and personal touch. When everyone is highlighting the same brand qualities, you will need a unique approach to stand out.
Developing a Central Theme
A brand's central theme acts as a pillar. It summarizes your company's principles and objectives in a single statement, or perhaps one word. It's a lot simpler to come up with marketing ideas and campaigns that connect with your company's philosophy and seem like a part of the brand.
Developing Your Brand's Individuality
Now, imagine your brand as a person, considering the preceding phases. You may gather every piece of information possible. The more specific you are, the more solidity your brand identity will have.
Brand themes may help you develop your brand's personality and story. Using themes, you may classify individuals and fictional characters based on a common set of personality qualities. These are commonly used in psychology and marketing.
Creating a Visual Brand for Your Business
Finally, create a visual illustration for your organization. This includes producing unique logos that represent your company's beliefs, selecting colors, designing your website and blog, and everything that can be related to visualizing your corporate brand.
Get familiar with geometric and color psychology, look at what prominent brands and other firms in your industry have done, and get on board with a good graphic designer to create the materials.
Best Channels for Manufacturers' Branding
Many businesses utilize social media, blogging with SEO suggestions, and email newsletters to boost their online presence. Content is the most important consideration when adopting these marketing methods. Hire good specialists to assist you in
understanding your buyer's persona and developing buyer-centric content to capture their attention and generate potential leads for your business.An active social media presence enables you to increase the number of followers on your social media sites and reach millions of people via these platforms. Furthermore, you can start weekly newsletters to keep your subscribers updated on the latest developments, campaigns, and how you're working to develop the best goods possible for your target groups.
Final Words
Effective branding for manufacturing is what you need to increase your company's popularity and demand in a competitive market. Once you've established yourself as a known brand in your sector, you may pursue manufacturer branding, which is used by many well-known manufacturers such as Ford, Nestle, Coca-Cola, and Apple. Use the above-mentioned techniques to create your own brand and stay ahead of the curve in your industry.
FAQ
What are the four elements of branding?
A successful brand requires a strong brand identity, brand image, brand culture, and brand personality, all of which must be present.
What is the manufacturer’s brand?
A product that has the manufacturer’s name on it or is used to market and sell the product.
What is manufacturers’ label?
The manufacturers label provides name and address of the manufacturer or distributor and relevant hazard warnings.
Read More
Article | January 20, 2022
COVID drove many supply chain disruptions in 2021. This was particularly true for companies using Asia to source product. Sadly, the bottleneck continues in 2022, but there are new channels now available to serve the North American material handling market. System integrators, dealers, and distributors in the space cannot work with vendors who offer slow delivery timetables. Customers want shelving, racking, conveyors, and robotics no later than Q3 2022.
MODEX 2022 provides answers to solve the supply chain disruption
MODEX 2022 (March 28-31, 2022) in Atlanta, will once again bring many global manufacturers to the event. Nearly 800 exhibitors and 40,000 attendees will respect COVID health and safety protocols while learning about much needed solutions from a variety of global manufacturers. For the first time there is an African company exhibiting at MODEX: LinkMisr International.
Booth #C5475
Read More