Tips for Competitive Manufacturing Strategies

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

Here's another #swisslathe valve part we helped a customer re-shore to USA⚙️🇺🇸 Pro-tip: you MUST find ways to be *price competitive* - we do it by using #lean methods, automation and running 24x7 "lights out" to give customers China-busting low prices yet still with aviation level quality and of course also resulting in a more local and stable supply chain. "But we sell based on quality" 👈🤡 Every shop says the same thing about their great quality and delivery -- it's an *expectation* -- not a selling point! You don't have to be the cheapest but you can win more business by beating the competition on costs - through *innovation* - not just slashing your price. And there are lots of strategies for unattended machining too... it doesn't have to be all or nothing. Fact: your machine has **168 hours** of capacity per week. It's not the machine's fault you only run it on day shift 5 days a week. Ok so maybe you can't get to 24x7 right out of the gate but they key is to ask yourself "what CAN you do?"" Maybe it's multiple vises on your milling table so you can run 4-6-8 of a part's 1st op instead of one at a time. Maybe it's a rotary indexer so you can fixture dozens of parts on all sides Maybe it's a bar fed lathe that does the 1st op and then feeds a mill to complete a 2nd op as a workcell with one person operating both for one piece flow? Maybe it's a now waaay more affordable small robot that can handle materials and slugs, peform flipping ops or even transfer between multiple machines. Again, the key is "what CAN you do" to add a few more hours of capacity. You don't need to be a Lean expert with depth of knowlege in #OEE to understand the value of when you add even (1) more hour of capacity per day. Now multiply that 1 hour x multiple machines and pretty soon you are generating almost the same as a brand new machine's additional capacity. This is the way. Strive to output the same, OR MORE, production as the typical competitor who us running with 3x the machines (and staff) as you, because you are getting closer to 168 hours of capacity output. 💡Summary: Make 168 hours of capacity your goal on every machine, and make continuous improvements to get closer and closer to it. #machining #machineshop #leanmanufacturing

🚀 What Manufacturing Can Learn from the 𝐀𝐮𝐭𝐨𝐦𝐨𝐭𝐢𝐯𝐞 𝐈𝐧𝐝𝐮𝐬𝐭𝐫𝐲 🏭⁣ Unlocking the Power of '𝐁𝐚𝐭𝐜𝐡 𝐒𝐢𝐳𝐞 𝐎𝐧𝐞' and '𝐂𝐥𝐨𝐬𝐞𝐝 𝐋𝐨𝐨𝐩 𝐌𝐚𝐧𝐮𝐟𝐚𝐜𝐭𝐮𝐫𝐢𝐧𝐠': ⁣ ⁣ In today’s fast-paced, demand-driven market, the concept of 'Batch Size One' is revolutionizing manufacturing. This approach, commonly known in the automotive industry as Just-In-Time (JIT) and Just-In-Sequence (JIS) manufacturing, is especially prevalent among major European brands. Here, vehicles are built precisely to unique customer orders, ensuring that every car rolling off the production line is tailored to individual preferences.⁣⁣ ⁣ By leveraging a data-driven approach, modern production lines can dynamically adjust to the unique requirements of each product. This involves smart integration of Bill of Materials (BOM), Bill of Process (BOP), and product-specific machine settings. Imagine a production line where machines automatically tweak parameters like speed, temperature, or tooling—drastically reducing changeover times and enabling efficient, customized production.⁣⁣ ⁣ The benefits of adopting a Batch Size One strategy are significant:⁣⁣ ⁣ 𝟏. 𝐇𝐢𝐠𝐡 𝐂𝐮𝐬𝐭𝐨𝐦𝐢𝐳𝐚𝐭𝐢𝐨𝐧: Offer products tailored to individual customer preferences, enhancing satisfaction and commanding premium pricing.⁣⁣ ⁣ 𝟐. 𝐑𝐞𝐝𝐮𝐜𝐞𝐝 𝐈𝐧𝐯𝐞𝐧𝐭𝐨𝐫𝐲 𝐂𝐨𝐬𝐭𝐬: Minimize the need for large inventories, cutting storage costs and reducing the risk of obsolescence.⁣⁣ ⁣ 𝟑. 𝐋𝐞𝐚𝐧 𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧𝐬: Align production more closely with customer demand, improving resource utilization and cash flow.⁣⁣ ⁣ 𝟒. 𝐌𝐚𝐫𝐤𝐞𝐭 𝐀𝐠𝐢𝐥𝐢𝐭𝐲: Respond swiftly to market shifts, maintaining a competitive edge.⁣⁣ ⁣ Into the future Closed Loop Data-Driven Manufacturing takes it a step further by using real-time and historical data from sensors and smart devices across the production line. These data points are continuously monitored and used to adapt machine settings, targeting optimal performance at all times. This closed-loop approach not only enhances machine performance but also boosts overall production efficiency.⁣⁣ ⁣ Curious to learn more? Let’s discuss how this approach can transform your operations! 💬⁣⁣ ⁣ #DataDriven #Manufacturing #Industry40 #BatchSizeOne #JIT #JIS #SmartManufacturing #Innovation #LeanProduction #Customization #Efficiency

MES/MOM Solutions: Elevating Manufacturing Efficiency  Implementing a MES/MOM Solution can revolutionize your manufacturing, driving functional improvements for enhanced efficiency, visibility, and decision-making. Here's a condensed overview:   Real-time Data Visibility: Gain insights into machine status, production rates & quality metrics. Enable faster decision-making through real-time monitoring. Production Scheduling and Sequencing: Optimize processes, minimize downtime, & enhance resource utilization. Improve efficiency through advanced scheduling. Quality Management and Traceability: Ensure adherence to quality standards with real-time inspection. Enable traceability throughout the production process. Workflow and Process Standardization: Establish standardized workflows, reducing errors. Enhance consistency with standardized processes.    Work Order Management: Prioritize, assign, & track tasks effectively for streamlined operations. Ensure efficient work order management. Resource Management: Optimize manpower, equipment, & material allocation. Achieve efficient resource utilization. Reduced Lead Times  Streamline processes for reduced lead times. Respond quickly to market demands. Inventory Management: Minimize stock-outs through efficient inventory management. Enhance supply chain efficiency. Automated Data Collection and Reporting: Reduce manual data entry with automated reporting. Ensure accuracy and timeliness. Non-Conformance & Corrective Action Management: Identify and manage non-conforming products swiftly. Enhance product quality and compliance. Resource Maintenance & Equipment Efficiency  Gain insights into equipment performance, improving OEE. Optimize maintenance schedules. Energy Consumption Optimization: Track & analyze energy consumption data for cost reduction. Identify opportunities for energy optimization. Labor Tracking & Performance Analysis: Monitor workforce performance & measure productivity. Enhance labor efficiency through data-driven insights. Regulatory Compliance & Reporting: Ensure compliance with industry regulations. Streamline regulatory compliance processes.   Continuous Improvement Initiatives: Leverage data-driven insights for continuous improvement. Foster a culture of operational excellence. Integration with Enterprise Systems: Seamlessly integrate with ERP, SCM, PLM, & other systems. Enhance data flow & decision-making. Embrace MES/MOM capabilities to drive operational efficiency, elevate product quality, and achieve superior manufacturing performance #mes #strategy #manufacturers

Manufacturing Leaders Talk About Efficiency—But Who’s Actually Reducing Operational Strain? Everyone loves to talk about operational excellence. Optimized workflows. Scalable systems. Cost reduction. But when it’s time to actually improve efficiency—where does all that talk go? I’ve seen it too many times: A company launches an efficiency initiative, holds a strategy meeting, talks about reducing operational strain… and then? Nothing changes. - Teams still feel overloaded. - Outdated tools keep slowing progress. - Scaling creates bottlenecks instead of boosting output. Why? Because real efficiency isn’t about meetings or reports. It’s about fixing what’s broken—step by step, process by process. Here’s what actually moves the needle: ✅ Aligning Priorities – Eliminate conflicting goals between production, quality, and supply chain. Metrics don’t fix misalignment—execution does. ✅ Optimizing Workflows – Apply MTM and ergonomics to balance workloads. Overburdened operators lead to delays and quality issues. ✅ Scaling Without Chaos – Build modular, adaptable systems that grow efficiently. Expansion shouldn’t mean complexity and bottlenecks. ✅ Cutting Costs Smartly – Reduce waste without sacrificing capability. Slashing budgets without strategy kills long-term efficiency. ✅ Driving Real ROI – Cost savings must improve margins, not just look good on reports. A 2% OPEX cut that slows production isn’t a win. Operational excellence isn’t a buzzword. It’s an execution strategy. The best manufacturers don’t just talk about reducing operational strain—they engineer systems that make efficiency inevitable. - If it’s not executed, it’s not operational excellence. ♻️ Repost to lead real change!

Data without intelligence is potential; intelligence without action is waste. Databricks' 𝟐𝟎𝟐𝟒 𝐒𝐭𝐚𝐭𝐞 𝐨𝐟 𝐃𝐚𝐭𝐚 𝐚𝐧𝐝 𝐀𝐈 𝐑𝐞𝐩𝐨𝐫𝐭 showcases a decisive shift as industries transition from AI experimentation to widespread production, with manufacturing emerging as a standout sector. Companies are leveraging AI to optimize production, enhance quality control, and integrate operational data into decision-making processes. Key takeaways from the report include: • 𝟏𝟏𝐱 𝐢𝐧𝐜𝐫𝐞𝐚𝐬𝐞 in machine learning models reaching production, indicating industries are prioritizing real-world AI applications. • 𝟏𝟒𝟖% 𝐲𝐞𝐚𝐫-𝐨𝐯𝐞𝐫-𝐲𝐞𝐚𝐫 𝐠𝐫𝐨𝐰𝐭𝐡 in natural language processing (NLP) use in manufacturing, driving improvements in quality control and customer feedback analysis. • 𝟑𝟕𝟕% 𝐠𝐫𝐨𝐰𝐭𝐡 in vector database adoption, supporting retrieval augmented generation (RAG) to integrate proprietary data for tailored AI applications. • Manufacturing and Automotive lead the charge with a staggering 𝟏𝟒𝟖% 𝐲𝐞𝐚𝐫-𝐨𝐯𝐞𝐫-𝐲𝐞𝐚𝐫 𝐢𝐧𝐜𝐫𝐞𝐚𝐬𝐞 in adopting Natural Language Processing (NLP).  Would anyone have picked Manufacturing growing the fastest in NLP?!?! 𝐖𝐡𝐚𝐭 𝐭𝐨 𝐃𝐨 𝐰𝐢𝐭𝐡 𝐓𝐡𝐢𝐬 𝐈𝐧𝐟𝐨? If you’re still debating AI’s value, you’re already late to the game. Manufacturers are moving from “what if” to “what’s next” by putting more AI models into production than ever before — 𝟏𝟏 𝐭𝐢𝐦𝐞𝐬 𝐦𝐨𝐫𝐞 𝐭𝐡𝐚𝐧 𝐥𝐚𝐬𝐭 𝐲𝐞𝐚𝐫!  The most successful organizations are cutting inefficiencies, standardizing processes with tools like data intelligence platforms, and deploying solutions faster. This isn’t just about keeping up with the Joneses; it’s about outpacing them entirely. 𝟏) 𝐈𝐧𝐯𝐞𝐬𝐭 𝐢𝐧 𝐂𝐮𝐬𝐭𝐨𝐦𝐢𝐳𝐚𝐭𝐢𝐨𝐧: Use tools like Retrieval Augmented Generation (RAG) and vector databases to turn AI into a competitive advantage by integrating your proprietary data. Don’t rely on off-the-shelf solutions that lack your industry’s nuance. 𝟐) 𝐀𝐝𝐨𝐩𝐭 𝐚 𝐂𝐮𝐥𝐭𝐮𝐫𝐞 𝐨𝐟 𝐒𝐩𝐞𝐞𝐝: The report highlights a 3x efficiency boost in getting models to production. Speed matters — not just for innovation, but for staying ahead of market demands. 𝟑) 𝐄𝐦𝐛𝐫𝐚𝐜𝐞 𝐎𝐩𝐞𝐧 𝐒𝐨𝐮𝐫𝐜𝐞 𝐚𝐧𝐝 𝐂𝐨𝐥𝐥𝐚𝐛𝐨𝐫𝐚𝐭𝐢𝐨𝐧:  The rise of open-source tools means you can innovate faster without vendor lock-in. Build smarter, more cost-effective systems that fit your needs. 𝟒) 𝐏𝐫𝐢𝐨𝐫𝐢𝐭𝐢𝐳𝐞 𝐀𝐈 𝐟𝐨𝐫 𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧𝐚𝐥 𝐆𝐚𝐢𝐧𝐬: AI isn’t just for customer-facing solutions. Use it to supercharge processes like real-time equipment monitoring, predictive maintenance, and supply chain resilience. 𝐅𝐮𝐥𝐥 𝐑𝐞𝐩𝐨𝐫𝐭: https://lnkd.in/eZCrq_nF ******************************************* • Visit www.jeffwinterinsights.com for access to all my content and to stay current on Industry 4.0 and other cool tech trends • Ring the 🔔 for notifications!

Manufacturing Automation – Strategy Starting out with Automation, it's best to understand the Current State FIRST! -- Walking on the manufacturing floor is the first and best ACTION to determine the "pain points" to SEE the DIFFERENCE between the procedures and what's actually being done in the process. Starting out with Automation, it's best to understand the Current State FIRST! -- "So how might we start? Think BIG – Act SMALL Surveying the plant, it is often easy to “see” process automation opportunities in many manufacturing steps that have remained mostly manual or with minimum automation. A typical signal is a manual operation performed at several manual or semi-automated stations on a product family. These can be assembly, test, inspection, adjustment steps, packaging or other secondary processing steps. The product may be produced upstream with high speed, automated equipment, (plastic molding is a good example), and this may be the final manual step, (degating, secondary finishing or mechanical assembly). Management’s response to this capacity challenge has often been a fluctuation of labor to meet demand, leading to significant added costs and other inefficiencies. “Throwing bodies” at the capacity problem as it were and those “bodies” are harder to find these days. Inefficiencies include labor cost/availability variations, quality variations and personnel training and turnover challenges; all impacting delivery and predictability! Another indicator for an opportunity to automate is that final, highly skilled operation that is so specialized and operator dependent that only a limited number of employees are qualified to perform this crucial manufacturing step. This often leads to lack of predictability as well as dependence on a select few members of the team while cross training becomes difficult and costly, especially when an employee leaves and that specialized knowledge leaves with him/her. In these and many other examples, the assembly steps may be manual or semi-automated simply because the status quo has been accepted with no manufacturing engineering or management investigation into further custom automation of that particular process, which could decrease overall costs. The problem is seldom technical, but rather managerial, as competing priorities for scarce capital have allowed this low hanging fruit to “die on the vine”, having never been identified." -- How do your survey the process to see if it's ready for 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 COLLABORATE on your automation for increased productivity. Adding value on the WHY, WHAT and HOW of Automation! What are you working on that I can help with? https://lnkd.in/ekeVSgCk #industry40 #automation #productivity #robotics