The Common Sources Of Loss In Manufacturing

Last Updated: 

May 15, 2024

Every business has its potential for inefficiencies and issues that can result in your labour and resources going to waste. In manufacturing, this problem can be particularly prevalent, which is why experienced hands in the industry have identified some of the most common sources of loss. Here, we’re going to take a look at those sources, and what you can do about them.

Key Takeaways on the Sources of Loss in Manufacturing

  1. Preventative Maintenance is Key: Regular maintenance and having replacement parts on hand can minimise downtime caused by equipment failure.
  2. Monitor Machine Efficiency: Train your team to recognize signs of wear and tear in machines to maintain maximum productivity.
  3. Effective Material Management: Proper storage and transportation of raw materials, like using bulk bag fillers, can prevent waste due to spillage and damage.
  4. Implement Quality Control: Clear quality control practices throughout production can catch defects early, preserving profits.
  5. Prioritise Workplace Safety: Invest in training, provide proper PPE, and conduct regular risk assessments to prevent accidents and injuries.
  6. Be Proactive: Actively identifying and addressing inefficiencies can significantly reduce their impact on your manufacturing process.
  7. Continuous Improvement: Regularly review and refine your processes to adapt to changing needs and minimise loss over time.
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Equipment failure

If you have a piece of equipment that isn’t working, then it is going to halt not just the step of the manufacturing process that relies on it, but all of the following steps that continue after it, creating a bottleneck. Performing routine preventative maintenance on your machines is vital, and you should have replacement parts for those that are likely to stop working first so that, even if a machine does fail, you have what you need on hand to get it up and running as quickly as possible.

Machine efficiency loss

A machine doesn’t have to stop working entirely for it to cause loss in your production line, of course. Many machines can experience wear and tear that can cause them to work slower and lose productivity. Training your team to be able to recognise these issues and to clean and maintain the machines they work with can make them much more likely to act quickly to maintain their maximum efficiency.

Material loss

Even if your machines are working perfectly, that isn’t going to matter if you aren’t able to effectively manage the materials that they use. Safely and efficiently storing and transporting your raw materials with the help of equipment like a bulk bag filler can prevent the spillage and damage that can often see these materials go to waste. You have to ensure that your materials are also kept in an appropriate environment to prevent them from spoiling.

Process defects

Even if your machines seem to be working fine, and your materials aren’t showing any problems, you can still spot defects coming out on the other side of the production process. Implementing clear-cut quality control practices throughout your production line can stop this from eating into your profits too often. By being able to identify the moment that a defect occurs, typically by checking between each step of the production process, you can more quickly act to fix it.

Accidents and injuries

Depending on where it happens, an accident or injury in the workplace can shut down production for several hours, if not an entire day. It’s important to prevent workplace injuries as much as possible, such as by ensuring that you train your workers in how to use the machines they’re stationed at, providing PPE to protect them from common risks, and performing risk assessments regularly.

There is no such thing as a manufacturing floor that is entirely free from the risk of loss. However, by identifying the problems below and taking steps to mitigate them, you can ensure that they play a much smaller role in the day-to-day of your manufacturing process.

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