Podcast: executive sessions – maximizing manufacturing with technology
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On MiddleGround’s twelfth episode of Executive Sessions, Clayton Gullet leads discussions with MiddleGround Founding Partner, Scot Duncan, and our Managing Director of Operations, Stan Stanford. This episode covers:
- Importance of Simple Technological Solutions in Manufacturing
- Bridging the Experience Gap in Manufacturing
- Real-time Shop Floor Management
Importance of Simple Technological Solutions in Manufacturing
In a fast-paced industry like manufacturing, emphasizing simple, cost-effective, and easy-to-implement technologies can significantly impact productivity and quality on the shop floor. Starting with basic, straightforward technologies over complex and expensive options reduces initial costs, minimizes the risk of implementation errors, and is flat-out more approachable for manufacturers and business owners.
Simple technologies allow immediate needs to be addressed quickly, with lower investment and risk. This ensures that the technological infrastructure within the facility evolves in a manageable and sustainable way.
The concept of “error-proofing” through design, known in Japanese manufacturing as “poka-yoke,” is a crucial focus. This approach involves designing systems or processes that eliminate the ability to make mistakes through human error, which saves time and resources that would otherwise be spent on corrections and adjustments. This proactive approach improves overall efficiency and product quality.
Bridging the Experience Gap in Manufacturing
The experience gap is widening in manufacturing. We’ve seen a shift from an average employee tenure of over 25 years to around 10-12 years. Gone are the days when workers were so in tune with the floor that they could even hear when a machine was starting to malfunction. This means that new strategies are needed to ensure production quality and efficiency are maintained despite the lack of experience.
Technology is instrumental in filling this gap. Advanced software and digital tools offer real-time support and guidance, helping inexperienced workers perform tasks more accurately and reduce process variability, ensuring products meet quality standards. For example, displaying visual work instructions on a digital screen can demonstrate to an operator where to place specific parts as they move through an unfamiliar process. These technologies facilitate continuous learning and skill development, enabling workers to quickly gain proficiency in their roles.
Real-time Shop Floor Management
Effective shop floor management is crucial for maintaining productivity and minimizing downtime. Many production issues stem from a lack of immediate problem detection. When a problem arises in one area, operators may not catch the issue until the end of a shift, causing a ripple effect that disrupts the entire shop. The implementation of real-time monitoring, through vision systems, allows managers to identify and address these issues as they arise. These technologies are instrumental in helping manage a shop and can detect errors that can be addressed immediately, saving countless hours of work.
Real-time monitoring of production processes also provides a comprehensive overview of the shop floor, enabling managers to track performance metrics and identify any inefficiencies. Having access to real-time data allows managers to make informed decisions that optimize production flow and allocation of resources.
Clear escalation procedures ensure timely responses to issues. When a problem is detected, prompt communication with the appropriate personnel is essential. This structured approach minimizes downtime and prevents small issues from escalating into larger disruptions.