Common Adversities in Production line and how to solve them

Problems

A sizable number of costs is waste in manufacturing due to inefficient systems and processes (poor manufacturing practices) or unfulfilled employee talent (inexperienced and unknowledgeable employees)  

To increase productivity, reduce lead time, and improve cost savings, getting a hold of waste is necessary. Manufacturers will see gradual—or even immediate—benefits once they take steps to reduce overall waste.

Solutions

1. Automation

Industrial automation can create more products in a shorter amount of time, eliminate human error, and produce near-identical products time after time. All three of these perks add up to major cost savings. 

2. Machines routine check 

Just by regularly checking your equipment (cleaning out dust and old grease, replacing parts, regreasing joints, and more), you can get the most out of the equipment you currently have. 

Problems

Many manufacturing assembly lines do not have the infrastructure or the tools to identify problem areas and analyze the entire assembly line process from one central location. Without accurate, ongoing, real-time information about your assembly line, you are not equipped to foresee potential issues or quickly react to them when they arise.

This problem is caused by failing to track real-time production information.

Solutions 

1. Tracking Equipment set up

Install equipment for tracking or fully automating the production system so it is easier to detect and anticipate possible bad outcomes 

And this equipment had better integrate into the big general system to ensure the information funnel would not be fragmented and effectively used 

2. Studying production data

With all the IoT and connected equipment of today’s manufacturing warehouses, getting the details of production is easier than ever. Use human-machine interfaces or programmable logic controllers to view data as your machines are working and save reports to study and compare later. 

Problems  

The speed of manufacturing line changeovers can make or break your product output. Costly in more ways than one, lengthy changeover time is something no business can afford.

Solutions 

1. Closely calculating expected time for a production line 

To better prepare for changeover phase, IE department has to calculate this metric more precisely to form an almost absolute time measurement for a production line running which will help shorten no-working time of a production line 

2. Automation

 Instead of manual changeover with separated tasks, we corporate all phases into a integrated process run mainly by robots which help to remove all unnecessary inactive time.

Problems

Inventory management is a widespread problem in the manufacturing industry. Holding too little inventory can hurt both profits and the relationship with customers. Keeping too much inventory can be costly to store and difficult to sell

Solutions 

Integrate software and tracking processes 

Investing in the right software and processes to track and manage inventory to save manufacturers time and money.  

Real-time tracking enables manufacturers to monitor and manage the flow of raw materials. It also lets them track work in process and finished products. This level of insight means companies can prevent inventory issues by intervening at first sign of a problem. 

Problems

The complexity of machinery is what mainly contributes to injuries. Besides, the unfocused working attitude makes laborers make mistakes and hurt themselves

 Solutions 

1. Employees training 

Proper training, competitive compensation, and making sure every employee takes breaks are all effective ways to reduce injuries and employee turnover. 

2. Turn to automation

The development of automation technology, particularly for goods transferring and regulate production line make laborer cut off is not an over-imagined solution