The most effective way to minimize downtime in Manufacturing is…
Do Not Plan for It. This might sound obvious but it’s NOT…
Too often management fails to assign enough work to their employees. They tend to underestimate how much work someone can achieve when completely focused and working against the clock. Productivity shouldn’t depend on who is overseeing the project that day; all employees should always work as if the boss is watching to ensure maximum results.
" .always work as if the boss is watching .”
In some cases, employees are assigned an average of 4.5 hours of work for their 8 hour shifts. How logical is it to only hold employees accountable for slightly over half of a full day’s work, when they are being paid double the amount of productivity? This proves to be a complete waste of resources.
Will planning for less downtime be more effective? After applying the PDF Factor (Personal, Distractions, and Fatigue), management should expect at least 6.5 productive hours per employee/shift. When assigning only 4.5 hours, they are planning for 30% built-in downtime.
It should not stop there. Not only should management assign 6.5 hours of practical work, but they should provide employees with backup tasks in case they run into obstacles in their primary job.
Broken tools, other trades in the way, lack of materials, or additional reasons that prevent an employee from completing their tasks should not be expected, but it would be beneficial to prepare for hurdles in a way that denotes busy work and promotes some kind of advancement. This way, money spent truly is money earned.
The potential annual cost of downtime can be exemplified as follows:
- 2 hrs. X 500 Employees (Average production facility crew size)
- Multiplied by $49.00/hr. (Average burdened manufacturing hourly
rate) - Multiplied again by 257 working days per year equals..
$12,593,000 of Potential Annual Cost of Downtime
"Great accomplishments are not easy; easy accomplishments are not great.”
This example proves that adding downtime to the day can be quite costly. Being able to save your company wasted money from downtime would be a great financial accomplishment, though one must never forget: great accomplishments are not easy; easy accomplishments are not great. Avoid this blunder altogether by knowing what your employees are capable of completing. Assign designated tasks to ensure that their time is being properly utilized in ways that benefit the company.
Exploring the realm of manufacturing, this article delves into the strategies I have employed to minimize downtime effectively. Instead of assigning an insufficient workload, managers should aim to provide employees with enough work to keep them engaged and focused throughout their shifts. This not only prevents wasted resources but also ensures that the company’s investment in labor translates into tangible results.
Drawing parallels with parenting, I highlight the importance of preventive maintenance, continuous improvement, and fostering a culture of accountability. Efficiency and productivity are not limited to the manufacturing sector but also apply to other areas such as fatherhood and business.
Just as in manufacturing, effective planning and resource utilization are essential for me to manage my time and responsibilities. By recognizing my capabilities and assigning tasks accordingly, I can make the most of my available time, juggling my work commitments and family responsibilities more efficiently.
Similarly, in the realm of business, optimizing productivity is crucial for success. As entrepreneurs and business owners, we need to understand the capabilities of our workforce and assign tasks that align with their skills and expertise. How quickly a product is produced is secondary to quality; direction is more important than speed
" .direction is more important than speed.”
By avoiding underestimation and providing meaningful work, our businesses can maximize our employees’ potential and drive growth. Additionally, preparing for potential obstacles and providing backup tasks or alternative strategies can minimize downtime in business operations, ensuring a smooth workflow and enhancing overall productivity.
When we implement robust processes and empower teams, we can optimize productivity and drive operational excellence.
