Disruptions happen daily at factories around the globe, causing significant damage to production processes. According to Statista, there’s an estimated loss of $184USD million in 2021 due to supply chain disruptions globally.
No manufacturing business is immune from these issues, but you can take steps to mitigate them and ensure resilient operations. The manufacturing space is constantly evolving, and manufacturers need to stay on top of new technologies and innovations to improve their efficiency and productivity.
Here are some tips for resilient manufacturing operations:
1. Use an inventory management system (IMS)
Inventory management in manufacturing is complex, especially when you have multiple locations with different resources and suppliers. An inventory management system helps eliminate errors by automating manual tasks and providing visibility into where products are located and how much stock remains. It also provides real-time data about product availability and lets you know if any items need replenishing before they run out.
Statistics revealed a total of $71.4USD billion loss due to insufficient inventory levels, wherein products sold or promoted are products that are actually not in stock. These numbers imply that having an effective inventory management system is crucial for maintaining efficient operations.
2. Optimise your IT infrastructure
Manufacturing companies often rely heavily on technology to keep their operations running smoothly. However, outdated IT systems can lead to downtime and slow down productivity. To avoid this, optimize your IT infrastructure to support all your needs. Optimization includes upgrading hardware and software, as well as implementing cloud solutions.
Cloud computing has become increasingly popular among manufacturers. Forbes reported a 92% increase in businesses relying on the cloud over the past decade because it allows them to access information and applications anytime, anywhere.
With cloud solutions, you can maximize virtualization to create a single operating system instance across multiple servers, reducing costs and improving performance.
3. Implement a quality control program
Quality control programs are essential for ensuring the safety and reliability of manufactured goods. They provide detailed documentation of each step involved in the manufacturing process, including materials, procedures, and equipment. Quality control programs also include inspections to verify that standards are being met throughout the operation.
Implementing a good quality control program that meets your specific requirements saves you from costly mistakes by identifying issues early on and preventing them from becoming major complications later on.
4. Use data analytics to make informed decisions
Data analytics provides valuable insights into how well your company is performing. With this information, you can make informed decisions that improve productivity and profitability.
Manufacturing operations are complex. They involve multiple steps and different types of equipment. Data analytics can help you track every aspect of your operation to make smart, timely decisions.
5. Keep up with regulatory compliance
Regulatory compliance is a critical aspect of manufacturing. Manufacturers must comply with various regulations to protect consumers and employees. Some examples of these regulations include those from the Occupational Safety and Health Administration (OSHA), Food and Drug Administration (FDA), and Environmental Protection Agency (EPA).
These rules govern everything from workplace safety to environmental protection. If a manufacturer fails to meet these requirements, it could face fines and penalties. Therefore, manufacturers must stay abreast of new laws and regulations.
6. Train your workforce
Training plays a vital role in improving employee skills and knowledge. Trained employees tend to perform better than those who don’t. When employees understand what they’re doing, they’ll work more efficiently and produce higher quality results.
A 2019 report by Statista reveals that manufacturing companies spend an average of $1308USD per worker annually on training because they know that investing in training will improve their bottom line. It’s not just about providing technical knowledge; workforce training should also focus on soft skills like leadership, communication, problem-solving, decision-making, and teamwork.
7. Develop a strong relationship with suppliers
Lastly, suppliers play a crucial role in manufacturing processes. Without them, there’d be no products or services available. As such, manufacturers must build long-term relationships with their suppliers.
It means establishing trust between both parties by communicating openly and honestly. It also involves knowing your supplier’s business model, strengths, weaknesses, and culture. By building a solid foundation with your suppliers, you can achieve mutual success.
To run a flawless and successful manufacturing operation, you must consider these tips. You may have heard or used some of these before, but it’s always good to review them. Remember, creating a detailed plan and sticking to it is the best way to ensure a resilient manufacturing operation.