Manufacturing continues to become increasingly competitive with margins getting ever tighter. Manufacturing enterprises must look ever more closely at their efficiencies and productivity and constantly re-evaluate the use of known technologies, while also considering newer technologies to introduce competitive advantages.
Manufacturers need ongoing evaluation of how to meet customer demands and possibly transforming the core operations of their business. Significant changes are happening to the factory floor, making it faster, more automated and more connected. Building and improving a digital backbone may will improve levels of productivity that will drive growth and profitability, but the challenge remains not just the “what” but also the “how”.
Methods to improve factory productivity:
Creating a digitally connected smart factory provides manufacturers with the ability to monitor and analyse multiple factory variables simultaneously including the performance of machines, people and processes. This enables them to find previously undetected problems and to identify strategies to make improvements. Here are some simple ways to enhance factory productivity.
Measure to manage: Analyse labour and machine costs by shift, product, or work cell and operator
Costs can quickly get out of control in a manufacturing or distribution business – money and time can be wasted with redundant processes, too much manual work and excess paperwork.
Recognise preventable downtime and reduce bottlenecks
Downtime hurts the bottom line, increase costs and hurts customer satisfaction. Downtime frequently results from bottlenecks, so detecting them is key to fixing them. Many bottlenecks have similar root causes, such as machine problems, supply chain issues, poor raw materials planning, staff underperformance, or poor factory floor layouts.
Quantify machine productivity, product quality and identify labour issues
World-class manufacturing standards within the factory require measuring equipment and labour effectiveness and performance. Detailed analysis of individual equipment and people performance with supporting data should include a record of the issues encountered.
Assess efficiencies operationally and identify areas requiring improvement
Manufacturers over the years have continued to strive for operational efficiency, even though a significant improvement would require a fundamental shift in their business model. Some manufacturers have implemented programs like Total Productive Maintenance (TPM) and focused on improving Overall Equipment Effectiveness (OEE) with the same aim of streamlining manufacturing process and increasing output
Implementation of Manufacturing Operations Management (MOM) techniques and systems can help to build on the capabilities provided by their ERP systems. Digitalising the manufacturing operation will help support development of new of products, creating new alternatives for customers, and improve competitiveness.
Triflex Automation and Controls Pty Ltd as a major supplier of industrial automation equipment understand the needs of the modern manufacturer and has the ability to assist regards of the size or budget restrictions. If you need assistance to find what is right for you, our experienced staff are available to assist and guide you to solutions that will enhance your factory productivity through automation.