Increase productivity in the metalworking industry

“I need to lower production/operation costs” / “I do not meet the delivery deadlines committed to the customer” / “I have many resources allocated to the operation” / “Quality problems affect productivity levels” / “I do not feel that my employees are committed to the company” / “I do not have reliable management indicators for decision making” / “All decisions go through me”

Do you feel identified with any of these statements? If so, it is because the most relevant problems that you must correct are:

• Lack of optimization of the available space.
• Disorder in the workplace.
• Inadequate storage systems at workstations and in common spaces.

In general terms, it can be said that your company is a safe candidate for the implementation of improvement tools that allow it to eliminate the inconveniences present in the development of its activities to guarantee greater productivity.

<<< Layouts: Strategic planning in the metalworking industry >>>

This happens because the needs that the metalworking industry has to meet are increasingly complex to satisfy since it must carry out faster processes and with the highest quality to distinguish itself from the competition. Due to this, customers become more demanding when it comes to choosing the best option for their businesses, so it is essential to have the best technology, which will be reflected in the productivity of your company.

Thanks to the different innovations that have been developed over the years, today you can count on different options that will help you achieve the increase in productivity that you are looking for for your metalworking industry.

As the old saying goes, time is money. The more production you can squeeze out in a period, the more money you'll make, right? But if you've been struggling to improve production or even if everything is going well, there are several things you can do to increase performance without sacrificing quality or removing obstacles to reorganizing the way you work.

Here, you'll find six ways to increase productivity in your metalworking business:

1. Review your existing workflow

You won't know what can be changed until you know how everything works now. Three areas contain critical information to help you identify the necessary changes:

• People: Do you have people with the right skills in the right places? Do you have a project manager to keep the critical path visible and on track? Are the objectives clearly defined, realistic and safe?
• Processes: when was the last time you mapped your processes? Have you used value stream mapping to evaluate process improvement projects? Where are the weak points and bottlenecks?
• Equipment and technology: is all your equipment in good shape? Is the technology you rely on optimal for today's needs? How easy is it to make changes in production?

Before you make any changes, understand how everything works now. There is still value in the saying, "If it ain't broke, don't fix it." Unless you can identify a financial or security reason to make a change, think carefully about the value of the expected result.

<<< Hidden costs: impact of outdated processes >>>

2. Update processes and technology

Once you've reviewed and mapped your existing workflow, start identifying areas where processes and/or technology might need some updating or change. Processes that have been in operation for a long time can be plagued with workarounds as new equipment is added or production methods change.

Automation is a powerful tool to increase efficiency and reduce errors. New software solutions can help you with scheduling, inventory, and monitoring workflow. Equipment upgrades can improve production speed and quality.

When identifying new technologies and equipment, consider the total cost of ownership and how it will affect the result. A high upfront expense pays off if the total cost of ownership is less than the technology or process it is replacing and if it solves a problem such as eliminating a production bottleneck or reducing scrap.

3. Commit to scheduled maintenance

The fastest way to slow things down is by ignoring regular maintenance. Maintenance downtime costs much less than downtime due to broken and worn equipment, therefore maintenance can be scheduled (breakage always comes at the worst possible time).

It is important that you: train all operators on regular maintenance and troubleshooting procedures schedule preventative maintenance at regular intervals identify the best time for maintenance using floor information and workflow processes.

Remember: preventative maintenance will ensure your equipment continues to run smoothly without unexpected downtime or work interruption.

4. Train employees

Employee education and training is an ongoing process. In some industries, certain types of training are required, such as daily safety training for all staff using safety equipment. Don't forget that new equipment and technology require training to get the most value. Employee education is also a great retention tactic, this is important because new hires take time to become proficient, causing a slowdown in production.

<<< Why is it so important to train your employees? >>>

So schedule training meetings for all employees when new equipment is installed, keep accurate training records, and schedule upgrades if necessary. You can also offer educational opportunities to your employees who want to advance or gain new skills. Never limit the training and education of your team.

5. Organization of the workspace

Reducing movement and clutter saves time. Create the optimal layout of tools and materials for the job or process by removing unnecessary or unused tools and materials from the workspace.

Try to have organized storage to reduce the time searching for materials, documents, and equipment. Design the manufacturing floor to maximize efficiency.

Reduce travel time and distance wherever possible, i.e. if a product needs to be moved from one machine to another, is there a way to shorten the distance, orient the product, or move the product more quickly and safely to the next step in the process? Is there a software solution that could improve the programming?

Take into account that excessive movement is a sign of poor organization and can cost you a lot of time.

6. Maintain optimal inventory

If you have too much inventory, you need a place to store it and expect to be able to use it all. If you have too little, you risk wasting time waiting for more inventory. Inventory optimization is especially important if you follow lean manufacturing principles.

You can use a software tool to track inventory and create automatic shortage notifications. You may be able to allow vendors direct access to their inventory counts and automatically fill in needed supplies.

This will allow you to build relationships with favored vendors to gain accountability for part quality and on-time delivery; you will also be able to make predictions about the impact of particular shortages and establish processes to mitigate production delays.

Keep track of reject rates, quality declines, and late deliveries so you can rectify them with the supplier or find a new way out.

It's important to understand that increased productivity should be driven by deliberate change rather than quick "fixes" that may help in the short term but cause problems in the long term. Additionally, increasing productivity on employees can lead to burnout and turnover, as well as costly safety issues.

A thorough review of current production processes and equipment can uncover hidden bottlenecks that could be quickly remedied through process change or new technology. Training your employees and good organization will provide a safe workplace and could lead to new suggestions from the workers themselves about solving the problems they see every day.

Finally, higher productivity results in higher income and the opportunity to expand the business, take on more work, increase wages or purchase new equipment. Establish a policy to review your processes regularly. New manufacturing equipment, materials, and techniques arrive all the time.

You have to be prepared to adopt those that provide the most value for your company.