What do you do if process automation isn't improving your manufacturing plant's efficiency?

If automation isn't boosting efficiency, here's what to do: 1. Re-evaluate Goals: Ensure automation aligns with bottlenecks and inefficiencies impacting production. 2. Audit Automation: Analyze workflow. Are there unnecessary steps or gaps in automation causing delays? 3. Data Deep Dive: Check data quality feeding the automation. Inaccurate data can lead to poor outputs. 4. User Feedback: Gather user input on automation's effectiveness. Are there usability issues hindering efficiency? 5. Refine & Refactor: Refine existing automation and consider refactoring complex processes for smoother operation.

When process automation isn't improving your manufacturing plant's efficiency, start by conducting a thorough audit to identify bottlenecks and inefficiencies in the automated processes. Ensure that your technology is properly integrated and that employees are adequately trained to use it. Evaluate if the automation tools are the right fit for your specific needs and consider upgrading or customizing them. Involve cross-functional teams to provide diverse perspectives on the issues, and be open to iterative improvements rather than expecting immediate, large-scale results. Continuous monitoring and feedback loops are essential to fine-tune the processes and achieve the desired efficiency.

Manufacturing is one industry which is being running from ages and Process Automation wise this is understood to be very difficult for automation to penetrate. Redesigning though not an early strategy but it is a methodology you need to adopt when you see that regular methods aren’t yielding efforts that we seek. But the key here is not transform everything at once as it’s not a budget friendly strategy, thus we need to start where we are in need the most and then explore other areas.

Process reengineering involves fundamentally rethinking and redesigning workflows, reconfiguring machinery layouts, or replacing outdated systems with advanced automation solutions. While this approach requires substantial commitment and resources, it can lead to significant efficiency improvements and transformative results when executed properly.

Without proper training, automation may be underutilized or misused, diminishing its benefits. Investing in comprehensive training programs enables employees to fully leverage automation technology. Additionally, ongoing support is crucial for promptly addressing issues, ensuring the system operates at peak performance and efficiency. This approach helps maximize the value and effectiveness of automation in the workplace.

It's always a 'loop hall' when Automation is designed or being coded, solution must be a robust and low code. many times designer don't know how to formulise the code because it is not properly documented or explained, many times designer was forced to keep the code flexible hence ir became low reliable, during FATs code doesn't go with full life cycle testing, during SATs user don't have full infra setup to check the code, these are the loop halls if both party pay their full attention and document every odds and evens within code testing and try to minimise the space of later improvement, you won't get chance to blame the system. Its us who design, its us who draft and it's us who test and it's us who blame system.