The Darker Side of Manufacturing
Himanshu Raj
Business Transformation for Apparel, Leather Goods, & Footwear Industries || Servant Leadership Practitioner || Manufacturing Excellence
Imagine a factory where, to overcome production failures and meet shipment deadlines, the solution is to lock people inside and force them to work over 18 hours a day regularly.
Sounds unthinkable, right?
But it happens.
I witnessed a disturbing practice at a factory, where employees were trapped to force overtime. The business owner shockingly boasted about a senior leader locking the gates to ensure 100% attendance.
This approach is not only morally reprehensible but also perilous. It demonstrates management's fundamental failure to address underlying issues and instead resorts to coercive tactics.
The consequences of such actions are far-reaching:
?? Undermines trust and morale
?? Fosters toxic work culture
?? Increases stress and burnout
?? Compromises employee well-being
Celebrating such methods as successes reveals a troubling lack of understanding and willingness to solve problems effectively.
Effective leadership demands problem solving & empathy, not exploitation.
In manufacturing, challenges like shipment delays are inevitable. But the real question is:
How do we address them?
There can be one or multiple reasons for delayed shipments from the below:
??? Poor material supply
?? Inadequate planning
?? Ineffective coordination
?? Quality control problems
?? Inefficient processes
?? Outdated systems
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?? Ineffective management
These are problems that are pushed onto employees, forcing them into excessive overtime as a quick fix.
A Better Way Forward: Science, Not Bullishness
The approach of locking employees in a factory is not just inhumane—it's illogical. It reflects a mindset that prioritises short-term gains over long-term sustainability and employee well-being.
What's needed is a shift towards scientific management principles and a commitment to continuous improvement.
10 Steps to Reduce Shipment Delays Without Destroying Morale:
1. Reduce the operating batch size ??
2. Make material flow visual ??
3. Design your optimal line size—avoid long lines that increase inventory and changeover losses ??
4. Combine shorter lines when work content is high ??
5. Implement a Visual Dynamic planning system to improve response time ??
6. Design a compact layout to reduce inventory delays between processes ??
7. Strengthen your internal supply chain—connect every process ??
8. Move away from departmental layouts—they're from the Stone Age ??
9. Monitor Throughput time as a KPI to track internal lead time from RM to FG ??
10. Be Modular—flexibility is key ??
The Bottom Line
It’s time to move away from outdated, unethical practices. The future of manufacturing lies in smarter, more humane solutions that ensure both productivity and employee well-being.
Are you ready to make the shift?
#Manufacturing #Leadership #ProcessImprovement #EmployeeWellbeing #ContinuousImprovement #SustainableManufacturing
Leading Expert in Footwear Manufacturing | White Label Solutions | Empowering Global Brands with High-Quality Production | Strategic Leader & Managing Director at Felix Impex Pvt. Ltd.
5 个月Absolutely agree! The well-being of employees should always be a top priority in any industry, including manufacturing.