August 31, 2023 Unexpected Ways Manufacturers Can Improve Productivity

Identifying methods to improve efficiency and strengthen manufacturing performance.

The global manufacturing market has reached unprecedented levels of competition, with customers placing more value on the speed of delivery and convenience than ever before. A Deloitte analysis shows that globalization, technological advancements, changing consumer preferences, and evolving government policies are dramatically accelerating the pace of competition among manufacturers – setting higher standards around company performance.  To provide the best possible service, manufacturers are seeking methods to increase productivity and efficiency without placing increased demand and stress on their workforce.

The process for driving productivity does not always require a massive overhaul of technology or equipment but can also be driven by smaller incremental improvements. The key is to have a system in place to unearth and implement those slightly less obvious solutions for driving productivity.

Begin with small, incremental improvements

Maximizing productivity levels begins with understanding where on the shop floor there are opportunities to reduce process or motion waste, ultimately freeing up time and resources for activities that add value. With this strategy, the goal is to identify root causes of issues and resolve them one by one. Over time, these small but continuous adjustments will lead to increased shifts in productivity.

The involvement of machine operators is critical in identifying where obstacles arise day-to-day, as they work closest to the zones where these arise and therefore can properly analyze production layouts and process flows for increased efficiency. Involving core members of the manufacturing workforce in the problem-solving process is essential to leading successful change.

When examining operations and layouts with a highly scrutinous lens, manufacturers are likely to save their employees valuable time every day by reducing unnecessary interruptions. By placing supplies and wipers nearby, manufacturers can impact the amount of motion and inventory waste in their site. For example, a Tork study highlighted that 44% of workers are interrupted 20 times per day because they have to get and dispose of wiping and cleaning products. The same study also revealed that 74% take more wipers than they need if wipers are not close by. 

Implement a “everyone, every day, everywhere” model

In order to truly lead a change in productivity, and unturn and solve process errors, employees must be on board and motivated. Continuous improvement should be implemented by everyone, every day and everywhere across the organization – requiring a mindset shift.

Empowering employees is key to this step, and this requires going beyond creating a teamwork environment and encouraging operators to identify and avoid problems and make recommendations regarding their work areas. 

Understand why preventive maintenance matters

Lastly, establishing a preventive maintenance routine is central to fending off any problems that lead to downtime. Preventive maintenance is carried out by the operators themselves rather than by dedicated maintenance technicians.

The first component operators will address in preventive maintenance is basic cleaning, as research shows that 89% of machine operators believe it is easier to inspect and detect faults on a clean machine. Therefore, operators will have a better chance of identifying any issues when they maintain clean equipment.

Motivating operators to upkeep clean equipment requires ensuring that every workstation is properly equipped. By having cleaning tools close by, operators will not only be more likely to undertake autonomous cleaning, but they’ll also do it more regularly. By positioning wipers close to their points of use, inventory waste (such as when operators take more product than they need to avoid wasting time walking back and forth) will be reduced. A manufacturer of indoor temperature systems was using bulk wiping and cleaning supplies located in a central location when they approached Tork for ideas on how to improve workflow. Following an analysis of operations, the manufacturer changed their wiper products and implemented dispensers at operator workstations. This led to an 18% reduction in material waste, and 1.5 hours of wasted motion saved per shift.  

By implementing preventive cleaning routines, manufacturers can increase their bottom line through reducing the downtime of machines by proactively identifying and solving issues, improving access to check points and eliminating sources of dirt and contamination.

To remain competitive, today’s manufacturers should reevaluate their processes to improve productivity goals and meet heightened customer expectations for rapid delivery. However, improving performance does not always require a complete overhaul of technology and equipment, and can be achieved by implementing continuous internal and external improvements, empowering employees to own the improvement and cleanliness of their work areas, and driving autonomous maintenance practices.

Sue Serveiss is the Regional Marketing Manager for Industry at Essity’s professional hygiene business. Sue oversees end-customer marketing plans in manufacturing, food processing, transportation and maintenance for the Tork brand in North America. Tork is the global leader in professional hygiene and a committed partner to customers in more than 110 countries. Tork offers dispensers, paper towels, toilet paper, soap, hand sanitizers, napkins, wipers, and software solutions for data-driven cleaning. To learn more visit: torkusa.com.

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