Manufacturing Process Improvement: A Guide

Process improvement is key to any organization—perhaps more so in the manufacturing industry. If production lines are inefficient, wasteful, and costly, then productivity suffers and profitability dips. Continuous improvement is, therefore, crucial for driving business forward. Let’s take a look at 12 tried, tested, and effective process improvement techniques.

Understanding Manufacturing Process Improvement

Manufacturing process improvement involves reviewing existing processes and finding ways to optimize workflows, all while increasing efficiency and production. Using proven techniques, manufacturers can reduce waste and costs. The ultimate aim, of course, is to increase the return on investment (ROI) and overall profitability of the business. Additionally, this is not a “one-and-done” thing. It involves continuous improvement through data analysis, employee feedback, and adopting new technologies.

Why Implement Manufacturing Process Improvement Methodology?

If we dig deeper into the “why” we can see that continuous improvement initiatives bring many benefits:

• Reduced costs: This is the overarching benefit. The more efficient and less wasteful your production line is, the less it will cost you to run.
• Increased efficiency: Streamlining manufacturing workflows and automation eliminates bottlenecks.
• Waste reduction: Using clever process improvement tactics such as inventory management and production control can significantly reduce the amount of wasted materials and resources.
• Increased customer satisfaction: Your buyers benefit through reduced lead times, quicker responses, and improved product quality.
• Happier workforce: When employees can do their jobs efficiently and see continuous improvement initiatives taking place, their motivation and productivity increase.
• Quicker response times: An efficient workplace gives you the flexibility to respond to changing customer preferences and helps you maintain a competitive edge.
• Better workplace safety: Manufacturing typically carries a high risk of workplace accidents and injuries. Safety compliance can be greatly increased through better workplace organization and standard operating procedures.

14 Manufacturing Process Improvement Techniques

Now let’s look at the business process improvement techniques you can implement within your organization. It’s important to note that you do not have to use all of these methods. Rather, pick the ones that work best for your business, or look at your existing improvement processes to see how using these techniques can bring better results.

1. Standardizing processes

Process improvement starts with standardizing your existing business processes. Everyone needs to be on the same page in regard to what happens, when it happens, and how it happens. This is achieved by implementing standard operating procedures (SOPs); in other words, a single playbook of how your business operations work. Look at your existing processes and establish the following for each one:

• Best practices
• A uniform workflow
• Compliance and safety procedures
• Ongoing methods for continuous process improvement

Train your employees on the standardized processes so they follow the same workflows, and look at implementing process improvement technology to minimize errors and ensure consistency.

2. Lean manufacturing

Lean manufacturing focuses on waste minimization while maximizing production value. It’s an effective process improvement method for reducing costs without affecting the quality of your product. It works by first identifying the seven areas of waste within your business:

1. Overproduction: Creating more products than needed or before they are requested.
2. Overprocessing: Performing excessive work on a product that adds no value to the customer.
3. Inventory: Keeping excess materials, components, or products in stock.
4. Idle time: The time wasted when machinery and workers cannot produce.
5. Transportation: Excessive movement of inventory and materials between locations.
6. Movement: Excessive movement of people or equipment within the production process.
7. Defects: The number of faulty products that lead to customer dissatisfaction.

Once your problem areas have been identified, you can implement the process improvement techniques that focus on eliminating waste.

3. Six Sigma

Initially developed by Motorola in the 1980s, Six Sigma relies on statistical data analysis to improve business processes and limit the waste of resources. The focus of this method is to use benchmarks to improve output consistency and quality. Split into two frameworks, each features five stages: Existing processes: Define, Measure, Analyze, Improve, Control (DMAIC) New processes: Define, Measure, Analyze, Design, Verify (DMADV) Essentially, any resource or process that doesn’t provide value for the end user is regarded as wasteful and should be eliminated from the production line.

4. Kaizen

The Kaizen method is all about continuous improvement. Originating from a Japanese philosophy, its principles concern employee involvement and making small changes that lead to big improvements over time. Ask your workers to:

1. Identify issues or areas of improvement.
2. Analyze the existing situation.
3. Create solutions.
4. Implement the solutions on a small scale.
5. Analyze the results.
6. Standardize any successful outcomes.
7. Rinse and repeat.

This is one of the best methods for increasing employee engagement. If they feel their concerns are listened to and acted upon, they are more likely to remain motivated.

5. Automated and smart processes

We’re in the midst of an incredibly exciting time – Industry 4.0. The fourth industrial revolution, where industrial processes are merged with digital tools. The result is interconnected, smart systems that communicate with each other. For example, this technology can predict or flag machine breakdowns, streamlining workflows in real time. Additionally, robotic process automation handles repetitive tasks and reduces non-productive manual tasks. Workflow automation, software integrations, and task managers are now easily accessible and affordable. For example, HighGear is an AI-enabled, no-code solution. The software enables manufacturers to improve processes, task management, and workflows effortlessly.

6. Total quality management (TQM)

Total quality management (TQM) is a buyer-centric process improvement tactic. It focuses on data-driven quality enhancements across all areas of the business. Its principles lie in:

• Increasing customer satisfaction
• Employee participation
• Improving quality control
• Constant process improvement

It works by addressing customer needs at every stage of a workflow and asking how it will affect a user’s experience. Employee input and training are key for fostering a culture around quality awareness. Implementing quality control tools will also help.

7. 5S method

The 5S method was initially developed by Toyota. It’s a process improvement technique designed to improve efficiency and safety while reducing waste. The 5S process improvement steps and goals are:

1. Seiri – Sort: Get rid of unnecessary items.
2. Seiton – Set in order: Arrange tools and resources in a logical fashion.
3. Seiso – Shine: Keep work areas clean and organized.
4. Seiketsu – Standardize: Develop uniform, streamlined workflows.
5. Shitsuke – Sustain: Apply continuous process improvement techniques.

8. Value stream mapping

Value stream mapping is used in lean manufacturing to visually understand production workflows. From raw materials to the finished product. When laid out clearly, it becomes much easier to spot and rectify inefficiencies. It follows several steps:

1. Select which end-to-end process you want to focus on.
2. Map out the current-state process.
3. Identify waste, inefficiencies, bottlenecks, and other problems.
4. Use lean manufacturing methods to improve processes.
5. Design the future-state map and implement it.

9. Just-in-time production (JIT)

JIT is a popular business process management strategy that aims to minimize excess inventory and the resulting waste. Essentially, it works by only producing goods as and when they are needed. There are various ways to carry out this process improvement, including:

1. Investing in inventory control systems like barcodes and RFID chips.
2. Creating capacity planning strategies.
3. Using a “pull system” that only produces enough products to meet current customer demand.
4. Using workflow management software to optimize materials and movements on the production line.

10. Agile methodology

We often see agile methodology used in project management. However, it also applies to the continuous improvement of manufacturing processes. Like the Kaizen technique, this method focuses on making small changes to improve the flexibility of production processes. It relies heavily on team communication and feedback to identify problems and make changes as needed. One example of this is Tesla, which applies the agile process improvement methodology in its car manufacturing process. It consists of four key values:

1. Individuals and interactions over tools and processes.
2. Functional products and working software over extensive documentation.
3. Customer involvement and continuous feedback over contract negotiation.
4. Flexibility, adaptability, and responsiveness over rigid adherence to plans.

11. Root cause analysis

Root cause analysis is essential for business process management. It’s very effective in revealing the underlying causes of problems, defects, and inefficiencies. It can be used in conjunction with other process improvement methods to quickly identify what needs to change.

1. Clearly define the problem or defect.
2. Conduct observations, interviews, and other investigative methods. Gather as much information as possible. Also look for patterns and trends in historical data.
3. Use the 5 Whys method to determine the root cause. In other words, keep asking “why” until you get to the bottom of the problem.

12. Employee training and engagement

A lack of employee engagement and training can be a significant problem. As such, your process improvement efforts should also focus on this area. For example, poorly trained employees pose a higher safety risk and can damage equipment. On the other hand, unmotivated employees won’t do their jobs efficiently. Here’s how to develop an engaged workforce:

• Develop a structured program for training employees to the desired level.
• Cross-training employees reduces bottlenecks and minimizes downtime.
• Involve employees in your continuous improvement efforts.
• Implement reward and recognition programs and other incentives.
• Provide regular safety and compliance training.
• Foster a culture of accountability.

13. Kanban

Like value mapping, Kanban is a visual technique designed to improve business processes. It’s also very effective for eliminating waste and results in enhanced customer satisfaction. Kanban uses a column-based visual board to represent the different stages of work and is based on a few key principles:

• Limiting work in progress: Complete existing tasks before starting new ones.
• The Pull system: Work is only pulled into the next stage (column) when there are sufficient resources available.
• Continuous flow: Kanban strives for a steady flow of work rather than working in rigid silos or time boxes.

14. Preventive maintenance

Preventive maintenance should always form part of your process improvement initiatives. This is the act of inspecting, servicing, and repairing equipment proactively before it breaks down. In contrast, reactive maintenance waits until equipment fails before it is fixed, resulting in costly repairs and production line downtime, which causes bottlenecks and other issues. Therefore:

• Develop a preventive maintenance plan that focuses on equipment essential to production.
• Carry out regular inspections and stick to the equipment manufacturer’s recommended servicing schedule.
• Use predictive maintenance technology such as IoT sensors and AI systems.
• Train employees on how to clean and maintain equipment. You should also teach them how to handle easily-fixable problems and when to escalate larger issues.

FAQs

What is process improvement in manufacturing?

Process improvement in manufacturing is the systematic approach to optimizing processes. By applying process improvement methodology, manufacturing companies can increase overall productivity, reducing waste and costs without compromising product quality.

What are the 5 steps of process improvement?

The five steps of business process improvement are:

1. Identify areas of inefficiency and waste.
2. Analyze the cause.
3. Find solutions.
4. Implement the changes.
5. Continuously monitor and optimize.

How do you develop a manufacturing process?

To develop a manufacturing process, you must first define the objectives. Design the workflow, including the resource requirements, before you standardize the new procedures and test them. Optimize them based on your findings. Finally, the processes must be implemented fully and monitored closely.

What is the role of a process improvement manager in manufacturing?

A process improvement manager is responsible for analyzing and identifying production inefficiencies. They then implement the improvements necessary to increase productivity. They also ensure continuous improvement and manufacturing best practices throughout all business processes.

Final Thoughts

Using the right methodology will undoubtedly boost productivity and your bottom line. But you don’t have to do it alone. Task management software like HighGear allows you to effortlessly automate and optimize workflows. From process management to reporting and everything in between, our no-code software is simple and quick to grasp. We welcome you to contact us for a full demo of our software’s capabilities.