7 tips for optimizing your fabricating operation

Operations managers have an important and intricate job. Not only must they ensure a smooth flow of products in and out of the facility, they also need to optimize the manufacturing floor layout, promote timely order fulfillment, and maximize the efficiency of all procedures. Toss into the mix a strong focus on profitability, and operations managers certainly have a lot to juggle for the success of their business.

In the fabrication industry, some methods for optimizing processes can drastically increase efficiency and reduce waste. To stimulate success, you need a commitment to productivity and a willingness to try out new ideas. If you can increase spatial and work flow organization, simplify your fabrication tasks, and establish guidelines for data collection, your company can begin to see improved efficiency, higher productivity, and less waste in no time.

Following are the top things you should pay attention to when improving your fabrication process.

1. Look to Lean Management Principles

One of the most popular ways to improve almost any manufacturing process is to adopt a Lean management strategy. The ideology for lean management focuses on efficiency-promoting practices, improving operations continuously, and reducing waste. While these may seem like overwhelming endeavors, applying lean concepts helps companies provide a quicker turnaround on jobs.

Follow the key principles of lean management:

• Value—Define what your customer sees as "value," and seek ways to enhance this throughout the manufacturing process.
• Flow—Streamline work flow by simplifying procedures, organizing the manufacturing floor, and assigning the right people to the right jobs.
• Respect—Foster a culture of empowerment and trust that allows employees and customers to pinpoint imperfections for the future eradication of problems.

2. Analyze Your Work Flow

It's difficult to optimize your fabrication process without a good understanding of your current work flow. To get a solid idea of your present operations, identify everything necessary to fabricate a product, including the processes, people, and technology, as well as the communication, procedures, and resources necessary throughout the company.

Consider value stream mapping, an exercise that helps you monitor, assess, and identify areas for improvement. When you document your work flow processes (on paper or electronically), you can pinpoint areas in which you're losing time or quality. Eliminate processes that don't add value to the end product.

3. Pinpoint Errors and Correct Them Instantly

Recognizing common sources of problems in your process and correcting them quickly has a positive impact on the overall process. Oftentimes, in an attempt to improve manufacturing quality, companies fix the symptoms of a process failure rather than seeking out the root cause. Properly evaluating recurring issues reduces the risk of costly malfunctions later in the process.

When a mistake does arise — as errors are inevitable in any fabrication process — make sure employees are trained in fixing issues immediately, rather than waiting for the next shift to take over.

4. Get (and Stay) Organized

Organize your shop floor to ensure that employees have easy access to equipment and tools. The spatial organization of materials, tools, and manufacturing space cuts down on time spent moving and searching for items.

Clear away waste and unnecessary items, and store components in their appropriate areas (these areas should be within easy reach for those using the components most frequently).

Visual systems, such as job boards that convey instructions, show the status of projects, and display relevant information to staff, can be useful.

5. Maintain and Upgrade Your Tools

Machinery that breaks down on a consistent basis negatively affects your business. Service all of your fabrication equipment regularly to prevent downtime. A rigorous inspection process, including preventive maintenance, will help catch problems before they become too serious.

At the same time, remember that repairing your tools isn’t always the best solution for optimizing productivity. Outdated machinery slows down the manufacturing process, and sometimes installing new equipment is the better option. Many companies make the mistake of servicing broken equipment, even if replacement would be less costly in the long run. Keep in mind that new fabricating technology emerges every day. Staying competitive requires the occasional upgrade.

6. Communicate Realistic Goals

Many factors contribute to unrealistic goals and timelines — everything from production pressures and stringent deadlines to client expectations. Remember that optimizing the process doesn't mean pushing your workforce to accomplish more than is reasonably possible. You can boost worker productivity by setting clearly defined goals for quality and timeliness that are realistic to achieve.

Once you have goals in mind, communicate them properly to all employees. Create an environment of open and clear communication to promote productivity and reduce the chances of mistakes being made along the manufacturing line.

7. Frequently Gather and Use Data

Optimizing your fabrication process may not start with buying a new machine or investing in new employees. It's important to analyze the existing state of your operation; you may not be running at peak performance to begin with.

Find out which areas of your production process are underperforming, and keep an eye on the associated metrics. This will help not only to optimize your process, but to keep it optimized in the long run.

Record, and monitor, the results of upgrading to a new piece of machinery to see what effect it has on your operation. Keep an eye on your production numbers, especially after cleaning and organizing the manufacturing floor, to track process improvements. Gathering and using data gives you the information you need to improve your business for years to come.

From your team to your machines, remember that optimization comes from a comprehensive evaluation of existing processes and your ultimate goals.

What have you done to optimize your fabrication process recently? Do you have a strategy that you feel is particularly effective? Let us know in the comments below.