Where Time is Most Often Wasted in Manufacturing Processes

dirty-industry-stack-factoryThe rise and fall of a business can be often equated to its successful manufacturing processes. Creating a
product, distributing it, and reaping the profit rewards is the goal of any manufacturing process. However, there are some common pitfalls that affect nearly any industry. Take a close look at where time is most often wasted during manufacturing processes.

Poor Organization

A problem that plagues many manufacturing processes is simple organization. Assembly stations might have tools strewn about the table, or fastener cabinets may be entirely mixed up. These areas must have proper organization before the workday begins. If anything becomes mismanaged, it should be corrected before the next assembly run. Ideally, the organizational process will have some self-correcting measures where disorganization rarely occurs. Monthly inventory counts can be combined with reorganization to keep the business on track.

Few Robotic Implementations

With today’s technology advances, it’s only logical to implement some robotic sections within the manufacturing process. These automated robots might weld a housing together, or stack mechanical assemblies. Assembly-line managers must take a close look at every manufacturing area where robotics can be used. Only a handful of positions should be manned by employees. Productivity and precision increase when automation is widespread. It’s critical to invest in this technology to reduce waste.

Referring to Old Designs

Where employee participation is necessary, these assembly stations should have all of the updated designs. A component may have been updated with new assembly gaps and screw-torque specifications, for example. If the employee is unaware of these changes, they might conform to the old specifications. As a result, the product will fail under testing. An entire day’s worth of products might fail as the old design continues to be used. Each day, employees and their stations should be updated with the latest information.

Failure to Update Software

Computers are often used for both automated and employee-driven assembly stations. If the computer software isn’t updated on a consistent basis, however, it could freeze or generate poor-quality products. Companies need to put some investment into their software in order to keep the assembly line moving swiftly ahead. Company IT personnel should make it a goal to verify software at least once a month.

Ideally, you want an assembly-line manager with a degree in civil engineering. They might be an active designer of the product, and if an issue arises during assembly, the engineer can quickly devise a solution. Streamlined fixes and productive staff will create the perfect conditions for manufacturing success.

Brooke Chaplan
 

"Brooke Chaplan is a freelance writer and blogger. She lives and works out of her home in Los Lunas, New Mexico. She loves the outdoors and spends most her time hiking, biking and gardening. For more information contact Brooke via Twitter @BrookeChaplan."