Strategies for Improving Regional Manufacturing Performance

Unilever shows us: productivity isn’t just about buying better tech; it’s about building better systems of people and technology working together. As Unilever’s Global Head of Ops said, they don’t separate investment in automation from investment in people. That mindset, designing roles, routines, and decision-making to match what the tech enables, turns capital spend into a competitive edge. Here’s what internal Org Development & Org Design can actually do to make that happen in #CPG: 1. Make tech and talent one system, not two: How to: - Don’t bolt tech onto old ways of working. - Start by assembling cross-functional teams: operators, IT, managers, and have them co-design workflow and KPIs together, from day one. 2. Define the new decisions, not just the new machines: How to: - Map what decisions move closer to the front line or become automated. - Run facilitated workshops to clarify “who decides what now” and ensure everyone has authority to act where it counts. 3. Build fast-feedback learning cycles on the floor: How to: - Create standing weekly or daily “factory pulse” huddles to surface issues from the floor, test improvements, and adjust quickly, turning problems into improvements instead of waiting for reports. Why this matters: 1. Tech doesn’t fix bad structure. 2. You can buy smarter robots, but if your teams don’t know how to adapt and own the new ways of working, you’ll end up paying more for the same headaches. Unilever shows that the real payoff comes when OrgDev and OrgDesign shape the system to use the new tools well, and that’s how you build a manufacturing operation that can keep pace. https://lnkd.in/gnMd5Qcm #CPG #OrgDevelopment #OrgDesign #ManufacturingExcellence #TechAndTalent #Productivity

Stop measuring "productivity" and start measuring flow! Most manufacturing metrics focus on productivity - how busy people and machines are. But being busy doesn't mean you're creating value. In fact, maximizing resource utilization often destroys flow and hurts overall performance. Here are 5 flow metrics that matter more than productivity: 1/ Lead Time ➟ How long does it take for material to move from start to finish? ↳ This is the single most important indicator of your process health. 2/ First-Time Quality ➟ What percentage of work is completed correctly the first time? ↳ Rework is the invisible flow killer in most operations. 3/ WIP Levels ➟ How much material is sitting between process steps? ↳ Lower WIP = faster flow and fewer hidden problems. 4/ Takt Adherence ➟ Are you producing at the rate of customer demand? ↳ Neither too fast nor too slow - just in time. 5/ Response Time ➟ How quickly can you detect and resolve abnormalities? ↳ Fast response prevents minor issues from becoming major disruptions. Implementation steps: Step 1: Make these 5 metrics visible in your area Step 2: Reduce batch sizes to improve flow (even if it seems "less efficient") Step 3: Focus improvement efforts on removing flow barriers, not keeping resources busy Remember: A process at 70% utilization with perfect flow will outperform a 95% utilized process with poor flow every single time! --- Follow me Angad S. for more!

In manufacturing, some of the 𝐦𝐨𝐬𝐭 𝐜𝐫𝐢𝐭𝐢𝐜𝐚𝐥 𝐢𝐧𝐬𝐢𝐠𝐡𝐭𝐬 𝐥𝐢𝐯𝐞 𝐨𝐧 𝐭𝐡𝐞 𝐬𝐡𝐨𝐩 𝐟𝐥𝐨𝐨𝐫. Technicians, operators, and engineers see issues and opportunities in real time. But often, these insights never make it to the C-suite—or when they do, they’re buried in technical jargon that’s disconnected from business strategy. 𝐖𝐡𝐞𝐫𝐞 𝐭𝐡𝐞 𝐃𝐢𝐬𝐜𝐨𝐧𝐧𝐞𝐜𝐭 𝐇𝐚𝐩𝐩𝐞𝐧𝐬: 🏭 Shop Floor Perspective: Metrics like downtime, OEE, yield, or vibration anomalies are the focus. These are essential for operational decisions but rarely tied to strategic goals. 💼 C-Suite Perspective: Leaders want to know how these issues impact revenue, profit margins, customer satisfaction, or long-term competitiveness. Without this connection, valuable technical insights often fall flat. When this gap isn’t bridged, 𝐨𝐫𝐠𝐚𝐧𝐢𝐳𝐚𝐭𝐢𝐨𝐧𝐬 𝐬𝐮𝐟𝐟𝐞𝐫: Operational challenges remain unresolved because they’re seen as “just technical issues.” Investments in tools like AI or IIoT aren’t fully leveraged because executives can’t see 𝘰𝘳 𝘶𝘯𝘥𝘦𝘳𝘴𝘵𝘢𝘯𝘥 𝘩𝘰𝘸 𝘵𝘰 𝘶𝘯𝘭𝘰𝘤𝘬 their strategic value. 𝐇𝐨𝐰 𝐭𝐨 𝐁𝐫𝐢𝐝𝐠𝐞 𝐭𝐡𝐞 𝐆𝐚𝐩: 1️⃣ Translate Metrics into Business Impact: Instead of reporting downtime as “4 hours on Line 3,” say, “This downtime cost $50,000 in lost production and delayed delivery to key accounts.” Framing technical data in terms of revenue, costs, or customer outcomes creates alignment. 2️⃣ Use Relatable Analogies: Replace highly technical terms with simple comparisons. For example: “This predictive maintenance alert is like getting a check engine light—fix it now, or risk a costly breakdown later.” If you can quantify the cost of this breakage, even better. 3️⃣ Make Data Actionable: Executives don’t need every detail—they need a clear summary paired with a recommendation. For instance: “We’ve identified a bottleneck that could be eliminated with a $10,000 investment in automation. The ROI would be $100,000 in the first year.” 4️⃣ Involve Cross-Functional Teams: Foster collaboration between technical and leadership teams. Regularly schedule shop floor walks for executives to connect directly with operational challenges and successes. 𝐓𝐡𝐞 "𝐒𝐨 𝐖𝐡𝐚𝐭?": When technical teams and executives speak the same language, organizations unlock the full potential of their data, systems, and people. Leaders make smarter decisions faster, and technical teams feel valued and aligned with business goals. 𝐀 𝐐𝐮𝐢𝐜𝐤 𝐓𝐢𝐩: Great leaders bridge the gap between data and decisions. By connecting operational insights to strategic priorities, they create a culture of alignment and innovation that drives results. #Leadership #Manufacturing #industry40 #digitaltransformation

Since 2020 the food and beverage industry has been one of the three worst performing for industrial productivity growth. But the The Hershey Company and Will Bonifant showed what one of the industries top performers can achieve: ~$300mm in productivity gains. They did it with a sustained focus on manufacturing excellence over the past 10 years. Here are their five main initiatives. 1. Hershey Lean 2. Supply Chain 2.0 3. Physical Automation 4. Factory Automation 5. Digital Backbone Two of my big learnings. First, they are reinvigorating Lean and even rebranding Hershey Digital Lean. Second, they are spending over $1B on supply chain 2.0 and expanding new capacity… not to waste the opportunity, they are coupling digital with greenfield and brownfield expansion. In LNS Research’s latest study, Hershey was a Top 5 F&B company on productivity growth. Based on what I saw this week, I would not be surprised to see them achieve top 3 and be named a productivity pathfinder in 2026!

What’s killing your output? It’s not speed. It’s bad flow. One of my favorite exercises to demonstrate flow involves a simple challenge with ping pong balls. The rules: ✅ Everyone must touch every ball. (they signify an order going through the system) ✅ They must have air time. ✅ They must end where they started. ✅ How many can make it around in one minute? The first round is always chaotic. Balls get dropped (quality errors), people rush (overburden), and the process is inefficient. Then, we run the PDCA (Plan, Do, check, Act) cycle: adjust and try again. What happens? ✅ The fastest person doesn’t matter. The slowest sets the pace. ✅ Hand-offs are where the real losses happen. ✅ No one needs to work frantically: just establish flow. ✅ Expedited “hot” orders (white vs. orange balls) throw everything off. ✅ Moving those who drop balls most to the first step reduces errors. By the third attempt, teams almost always double output and cut defects by a third - or eliminate them entirely. The lesson? ✅ Optimizing one station means nothing if the system doesn’t flow. Most companies I help don't need more machines or more people or even higher OEE, they need better FLOW! 👉 Are you focused on local speed or total system effectiveness? 👉 Where does your team struggle with flow, and what’s one thing you’ve done to improve it? #LeanManufacturing #Flow #PingPong #Focus #Example PS: As a self-proclaimed ping-pong fanatic, I like to break out my Hi-Vis gloves (because all true ping-pong pros wear them, right?) and my undersized paddle-the perfect way to play my kids, keep it competitive, and still sharpen my skills. 👉 Are you a ping-pong pro, or just a casual challenger?

The #1 Key to Running an Efficient Business: 🚀 It’s Not What You Think ⬇️ Underutilized production can lead to: ✔️ Late deliveries ✔️ Supply chain disruptions ✔️ And ultimately may damage your reputation as a reliable supplier If you’re in the machining world, you’ve likely heard plenty of advice: ✅️ Invest in AI and faster machines.  ✅️ Use cutting-edge tools for precision.  ✅️ Analyze ERP software insights for time savings. While these are valuable, they’re not the game-changer in machine shop world. 🔑 The secret weapon in manufacturing is? Scheduling. Here’s why: 1. Monitored and Optimized Machine Utilization: ↳ Fewer idle workers and machines, more profit. 2. Streamlined Workflow:   ↳ Reduced bottlenecks, smoother operations. 👉Top 5 bottlenecks are: 👇 💠Engineering and Planning 💠Quality Control and Inspections 💠CNC Programming 💠Tooling and Tool Changes 💠Material Handling and Logistics 3. Shorter Setup Times:   ↳ Group similar jobs for faster production. 4. Minimized Downtime:   ↳ Maintenance planned during off-hours = fewer disruptions. 5. Enhanced Labor Productivity:   ↳ Clear schedules mean employees can focus on what matters. 6. Lower Costs:   ↳ Efficiency saves on energy, tooling wear, and more. 7. On-Time Deliveries:   ↳ Happy customers = repeat business.    There is correlation between scheduling issues and higher defect rates. A higher defect rates can impact brand reputation and customer satisfaction.   Too often, shops pour money into new equipment without addressing inefficiencies in scheduling, and that’s a missed opportunity. Here’s the truth: Scheduling might not be flashy, but it’s transformative.   ↓ ↓ ↓     💡 Now over to you:   How has scheduling impacted your shop? What strategies have worked best for you? Let’s swap insights! Video Credit: sylcomlight  #manufacturing #AI #SupplyChain #CNC #programming #engineering #MachineShop #ManufacturingExcellence #EfficiencyTips #OperationalExcellence ♻️ Repost this to help others in your network.         ✅ Follow Thomas Gutwa for more. 

I've talked about it time and time again… but labor constraints continue to rear their head, especially when demand for US manufacturing is projected to rise. What are the solutions... improve efficiency? Reduce the experience needed to run processes? Increase retention rates among existing employees? Tough break - it's all three. All business owners trying to solve this issue should consider technology as a way to adapt to the changing labor supply. Before you jump to the conclusion that I mean automating workers out of the factory, that's not what I'm suggesting. I'm referring to small tech tweaks that can have huge impacts on productivity. For example: 🔎 Use a simple vision system to support quality checks and hit a higher accuracy rate. 🚨 Using alert systems that notify floor managers of potential issues in real time when usually they would have to wait until the end of shifts to receive reports. 👩🏫 Add TV screens detailing steps of processes, so newer employees can get trained quickly and make fewer errors. These suggestions aren't $500,000 investments in big fancy equipment; they are low-cost, low-effort installs that focus on maximizing the labor you have and preparing for increased turnover and training needs for new hires. Check out our podcast on tech solutions to maximize manufacturing here: https://bit.ly/42MIQgw

Manufacturing Automation – Fundamental gains Incremental improvements sum to large GAINS! Assuming a process is functional and delivering product, it’s fair to assume that each step, task or sequence has opportunities for improvement in terms of LOCALIZED PRODUCTIVITY, whether we see those or not!  The probability that these opportunities are significant goes up, for a long running process. The drivers of this may include: -         Absence of any review due to avoiding a re-validation of the process. -         Lack of prioritization, as resources are focused on either fire-fighting or larger opportunities. -         General neglect driven by “this is the way we’ve always done it”. -         “If it ain’t broke don’t fix it!” The evidence that this is the case is ANECDOTAL, as it’s often the case that a new engineer or process supervisor to this type of process, takes keen INTEREST in his new fiefdom and proceeds to make incremental improvements that over the period of 6-24 months, accumulate to a significant bump in that processes’ PRODUCTIVITY, with minimal capital investments. Typical actions taken include: -         "Rearranging the furniture" to facilitate workflows. -         Updating and standardizing SOPs, eliminating worker to worker variations. -         Executing and instituting routine maintenance of tools and equipment. -         Controlling inputs to the process to assure conformance to specifications. -         Engaging the workers for incremental but continuous improvements. From an AUTOMATION or equipment perspective, the process review typically identifies the need for simple, worker ENABLING tools, semi-automated fixtures and even fully automated, stand-alone systems that are operator driven or controlled and significantly INCREASE high quality throughput. Aligned with: -         The worker performs Dexterity and Perception functions, while -         Machine does Power and Precision functions. This HIGH IMPACT automation is typically: -         Very cost effective. -         Utilizes proven low technology, consistent with what is already in the process. -         Requires little worker training or up-skilling. -         Conforms to the established process flow and does NOT disrupt or transform the process. IN SHORT: Boring, meat and potatoes AUTOMATION, focused on PRODUCTIVITY and nothing else! Incremental improvements sum to large GAINS! -- “The road to Industry 4.0 goes through Industry 3.0 …. There are No Short Cuts!” -- Are you ignoring the fundamentals in pursuit of Industry4.0 Automation? Your thoughts are appreciated and please SHARE this post if you think your connections will find it of interest. 👉 Comment, follow or connect to discuss how to collaborate and plan your automation for increased productivity. https://lnkd.in/eWHQiM2g #industry40 #automation #productivity #robotics