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Last updated on 2024年7月21日

Here's how you can address an underperforming manufacturing process.

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When your manufacturing process isn't meeting expectations, it can be a source of significant stress and financial strain. But don't despair; there are actionable steps you can take to diagnose and improve the situation. By systematically evaluating and addressing the factors that contribute to underperformance, you can turn things around. The key is to approach the problem methodically, using data-driven analysis and proven engineering principles to identify bottlenecks and implement effective solutions.

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Tanveer S.

GE Aerospace GET | Contributing to Precision Manufacturing and Learn the Ropes of Aerospace Innovation
Walter Moragne

Quality Management Consultant and Contract Auditor

1 Diagnose Issues

Before you can fix an underperforming manufacturing process, you need to understand the root causes. Start by collecting and analyzing production data to identify patterns or recurring issues. Look at machine efficiency, product defects, and throughput rates . Sometimes, the problem may be as straightforward as a single piece of equipment underperforming. In other cases, it could be a complex interplay of factors, such as workforce training, supply chain logistics, or maintenance schedules. Accurate diagnosis is the first critical step toward improvement.

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Tanveer S.

GE Aerospace GET | Contributing to Precision Manufacturing and Learn the Ropes of Aerospace Innovation
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Conduct a thorough analysis to identify the root causes of underperformance. Use tools such as root cause analysis, fishbone diagrams, or 5 Whys to pinpoint specific problems, whether they’re related to equipment, materials, or procedures. For example, if a production line is slow, investigate potential issues such as equipment malfunctions, bottlenecks, or inefficiencies in the process.

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2 Optimize Workflow

Once you've pinpointed the issues, streamline your workflow to eliminate inefficiencies. This could involve reorganizing the shop floor layout to reduce movement or implementing lean manufacturing principles to minimize waste. Consider using value stream mapping , a tool that helps you visualize the flow of materials and information through your production process. By optimizing each step, you can improve overall efficiency and reduce cycle times, leading to better performance.

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Walter Moragne

Quality Management Consultant and Contract Auditor
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I worked for a large company and we used lean manufacturing, Kaizen and Six Sigma methodologies. The main bottle neck is the understanding and involvement of Senior Management. In other words all such actions need to hit the bottom line and enhance customer satisfaction.

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3 Upgrade Technology

In some cases, outdated or inadequate technology may be holding your process back. Investing in modern machinery or automation can significantly boost productivity and quality. However, it's essential to conduct a cost-benefit analysis to ensure that the investment will pay off in the long run. Look for technology that not only increases speed but also enhances precision and consistency in your manufacturing process.

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4 Train Staff

Your workforce is one of your most valuable assets. Ensure they are well-trained and equipped with the knowledge to operate machinery effectively and troubleshoot issues. Continuous training programs can keep skills sharp and improve worker engagement. Moreover, fostering a culture of continuous improvement can encourage staff to contribute ideas for process enhancements, further boosting productivity.

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Walter Moragne

Quality Management Consultant and Contract Auditor
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I fully agree with all of these statements. Employee training can yield and engender company efficiency and synergy. I have training in my background both as a provider and a recipient. In my opinion, it is hard to train too much.

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5 Implement Controls

Quality control is paramount in manufacturing. Implement robust quality control measures to catch defects early and avoid costly rework or scrap. Statistical Process Control (SPC) is a method that uses statistical methods to monitor and control a process, helping you ensure that it operates at its full potential. Regularly reviewing these controls can help maintain high standards and prevent future underperformance.

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Tanveer S.

GE Aerospace GET | Contributing to Precision Manufacturing and Learn the Ropes of Aerospace Innovation
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Establish control measures to monitor and maintain process performance. Use key performance indicators (KPIs) and real-time monitoring systems to track progress and identify deviations. For example, implement quality control checks and automated alerts to quickly address any issues that arise.

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6 Review Regularly

Finally, make regular reviews a part of your routine. Continuous improvement is an ongoing process, not a one-time fix. Set benchmarks for performance and schedule regular audits to assess whether those benchmarks are being met. Adjust your strategies as necessary to keep up with changing demands and technologies. By staying vigilant and proactive, you can maintain a high-performing manufacturing process that meets your business objectives.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Tanveer S.

GE Aerospace GET | Contributing to Precision Manufacturing and Learn the Ropes of Aerospace Innovation
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Foster a culture of continuous improvement by encouraging feedback and suggestions from employees who are directly involved in the process. Engage in benchmarking against industry standards to identify best practices and stay competitive. Additionally, explore opportunities for cross-functional collaboration to address complex issues and enhance overall process performance.

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Here's how you can address an underperforming manufacturing process.

1

2

3

4

5

6

7

1 Diagnose Issues

2 Optimize Workflow

3 Upgrade Technology

4 Train Staff

5 Implement Controls

6 Review Regularly

7 Here’s what else to consider

Manufacturing Engineering

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Here's how you can address an underperforming manufacturing process.

1

2

3

4

5

6

7

1 Diagnose Issues

2 Optimize Workflow

3 Upgrade Technology

4 Train Staff

5 Implement Controls

6 Review Regularly

7 Here’s what else to consider

Manufacturing Engineering

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感谢您的反馈

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