5 Reasons Your Production Line Is Inefficient
Production inefficiency can break an otherwise successful company by accumulating waste and expenses.
Manufacturers of all industries, sizes, and phases can benefit from productivity analysis. This is especially true within production lines, where waste in the form of energy, materials, and money can negatively affect a company’s revenue.
Understanding production inefficiency, and how to reach peak production efficiency, will help manufacturers to remain competitive in their fields.
Learn more about how to fix production inefficiency in your manufacturing business below.
How to fix production inefficiency
What is production inefficiency?
To explain production inefficiency, let’s start with production efficiency.
Peak production efficiency, or productive efficiency, is when a company is producing the maximum amount of one good without wasting resources or lowering the production level of another good.
Production inefficiency is when resources are wasted, or when production levels are lower than their potential.
Production efficiency looks different for every company. However, each company can use similar guidelines to improve their production processes.
Causes of inefficient production lines
Determining the cause of production inefficiencies can be a complex job depending on the size and intricacy of the company’s manufacturing processes.
Examine your factory for these common causes of inefficient production lines and see where you can make changes for more productive operations.
1. MACHINE QUALITY AND PERFORMANCE
Industrial robots and manufacturing equipment need to be in prime condition to work as efficiently as possible.
Keeping a strict maintenance schedule is the easiest way to maintain machine quality and performance. If you notice that your equipment is beginning to slow down or use more energy than necessary, then consider sending it in for reconditioning. Reconditioning your equipment will extend its life by replacing old parts and cleaning out grease, dust, and other particles.
You can also replace equipment if it is more cost-effective than reconditioning and repairing it. Consider buying quality-tested used industrial robots and equipment with reconditioning treatment for the biggest bang for your buck.
2. EMPLOYEE KNOWLEDGE AND PERFORMANCE
Your employees can make a huge difference in the productivity levels of your business.
Educated employees who feel connected to their jobs and feel like a necessary part of the business are more likely to feel motivated to perform at their best and improve their work environment.
We have a blog post on how to build a strong production team and why it matters for the health of your company. You can read that here.
If you want to educate your staff in robotics for more capable and independent employees, take a look at NRTC Automation’s Robotic Training Services. We can personalize a plan for your company’s needs and give your employees the confidence to solve technical issues on their own.
We also offer Robotic Engineering Services for companies who need to hire qualified and experienced technicians. Visit our website for more information.
3. PRODUCT QUALITY
Poor product quality can make your production line inefficient. Using low-quality raw materials will not only create more waste, but they can create products that do not meet product standards that must be thrown away.
Even worse, low-quality end products can lead to customer dissatisfaction, which can destroy your company’s reputation.
Optimize product design with prototyping and use high-quality materials for the best end product. Doing so will lessen the chance of material waste and potential customer loss. An inexpensive way to prototype is with a 3D printer that can quickly produce parts and prototypes without waste. The upfront investment is well worth the cost-savings in product waste and customer retention.
4. SCHEDULE GAPS
Latent schedule gaps in your production process can cause production inefficiency when machines have the potential to work. Planned downtime has its benefits, such as reducing hourly usage and maintenance, but downtime in general can be costly for manufacturers.
Downtime can cost up to $5,600 per minute. If you have production schedule gaps that can otherwise be utilized, make the necessary changes to save on major downtime costs and improve production efficiency.
5. LACK OF SUSTAINABLE PROCESSES
Finally, an unsustainable factory creates waste in every part of the production process. Using sustainable manufacturing methods not only benefits the environment, but it will also improve your production efficiency and result in significant cost savings over time.
To get involved in sustainability, learn more about lean manufacturing practices such as kaizen or 5S. These methods can help you reduce waste and create a faster, more productive manufacturing line.
NRTC Automation can help you create a more sustainable production process by designing, building, and engineering a custom robotic work cell with refurbished industrial equipment. A robotic work cell will improve production efficiency and result in long-term cost savings by providing your company with flexible production.
Get competitive by improving production efficiency
Staying diligent with productivity analysis will help your company continue to grow by preserving revenue and resources. Check your factory for the causes of production inefficiency listed above to improve your business.
WORK WITH NRTC AUTOMATION TO GROW YOUR BUSINESS.
NRTC Automation is a trusted partner providing comprehensive industrial automation and manufacturing services. After delivering our services to top automobile manufacturers across the world for more than a decade, NRTC Automation is the destination for tear out services and robotic solutions.
We offer financing and free consultations to help manufacturers of all sizes and phases to grow their businesses. Visit us today to learn more at www.nrtcautomation.com.