The costs associated with downtime were never easy to absorb. In today's modern manufacturing plant, it’s become more important than ever to keep downtime to a minimum.
In 2023, a report by Siemen’s Senseye, revealed that unplanned downtime cost manufacturers at least 50% more in 2022 than it did between 2019-2020, with an hour of unplanned downtime said to cost over $2m in an automotive plant.
Furthermore, it’s estimated that the impact of downtime on British manufacturing is more than £180bn per year, and increased inflation and production lines working at higher capacities were said to be contributing factors to this heightened cost.
Keeping things Moving
Knowing what the problems are can be half the battle, but actually applying a fix that works long term is something else! We’ve put together some pointers based on conversations we are having with production managers across the board.
- Scheduled maintenance: A solid preventative maintenance plan is your best bet. This means knowing exactly what you've got, when it was last serviced, and what needs doing next. It's about working smarter, not harder, by preventing problems before they start. Make sure your maintenance plan ties into your overall business goals, so you're not just fixing things but improving the whole operation. This includes ensuring critical parts and suitable resources are available to complete the relevant jobs.
- Predictive Maintenance: One of the most common technical faults is the overheating of particular parts, especially where there is metal on metal, as these can short electrical circuits and cause the machines to stop running. Updated technology using machine learning algorithms (at the most basic) to AI (more advanced) can monitor performance 24/7. AI is being trained to not only collect data, but interpret it. Rather than receiving an assessment that needs to be checked, sophisticated systems can monitor, interpret requirements and notify the production manager. This level of automation analyses the production line to the nth degree of the machine’s performance – notifying supervisors in advance when performance strays from the norm.
- Spare parts should be available as an inventory: Having the right spare parts on hand is crucial for keeping production lines up and running. Without essential spares, even a small problem can turn into a major headache, causing costly downtime. It's like having a first aid kit ready for your machinery; you hope you won't need it, but when you do, you'll be glad it's there. By making sure we have enough of the right parts in stock, we can get machines back online quickly and keep production flowing smoothly. Purchase orders that are created when a spare part hits the minimum stock quantity threshold will enable sufficient time for stock to be replenished.
- Measure what matters with regular audits: Remember that it’s not just about keeping an eye on the numbers – you have to learn to optimise them to make meaningful improvements. It’s not good enough to simply rely on your gut instinct, production managers need to analyse the data and use it to make data-driven decisions.
- Communication systems: With the noise, shift work, and hands-on nature of the job, getting messages across is tough. Plus, let's face it, factory workers are often bombarded with top-down jargon that doesn’t really connect. To tackle this, production managers need to break down communication barriers by using simple, clear language and finding ways to reach people where they are, not where it's convenient for management. This might include text alerts or pre-shift messages to ensure the team knows what’s going on, what’s next and what items are up for discussion.
- Technology is a lifeline for efficiency: Technological advancements, such as artificial intelligence, automation, and robotics, offer UK manufacturing a pathway to increased efficiency, productivity, and competitiveness. While the initial investment and the need for upskilling the workforce can be challenging, the potential rewards are substantial, including improved product quality, reduced costs, and the ability to take on more complex manufacturing processes. Technological advancements are developing at pace, we’re still a few years from fully automated human robotics (even though BMW, Mercedes, Hyundai and Toyota, are testing the technology in their assembly plants).
- Continuous improvement: There is always room for positive change, even after tackling and resolving an initial crisis. Creating and implementing systems to monitor the plant's performance and identify new bottlenecks or inefficiencies, you can continuously spot opportunities and potential pitfalls.
Driving Talent Acquisition for the Manufacturing Industry
For over a decade, we’ve been at the forefront of connecting top talent with leading manufacturing businesses. We understand the unique challenges and opportunities within the industry, and our mission is to deliver exceptional recruitment solutions that drive your success.
With a proven track record of partnering with companies of all sizes, from innovative startups to established industry giants, we possess the expertise to meet your specific staffing needs. Our tailored approach ensures that we identify and attract the most qualified candidates who align with your company culture and strategic goals.
At the heart of our success is a team of industry-focused recruitment specialists. We combine in-depth knowledge of the packaging sector with a passion for finding the perfect fit. Our rigorous recruitment process, coupled with a dedicated training academy, guarantees that our consultants are well-equipped to deliver exceptional results.
By choosing us, you’re investing in a strategic partnership that goes beyond traditional recruitment. We’re committed to helping you build high-performing teams that drive innovation and growth within your organisation.
Let's discuss how we can elevate your talent acquisition strategy.
Phone: 0333 307 7777 | Email: enquiries@pioneer-selection.co.uk