In the world of modern manufacturing, the importance of an efficient supply chain cannot be overstated. A well-functioning supply chain ensures that a company has the right materials, at the right time, in the right quantities, to meet customer demand. However, achieving this level of efficiency can be challenging. One area that is often overlooked is the impact that the plant floor can have on overall supply chain performance and success.
Now, there is an old saying that “Knowledge is Power”. Manufacturers invest a great deal in resources to improve manufacturing efficiency and streamline their operations. When these companies are looking for answers to problems or to actually determine what the real problem is, they seldom turn to people who might be able to help the most, the workers on the line.
Operations and manufacturing managers always look at metrics on productivity, schedule adherence, downtime and other critical production data. Manufacturers are always looking for ways to produce more and make the shop floor more efficient. However, the focus is typically on equipment instead of looking at it from the line workers’ standpoint. There is a relatively new term in manufacturing that is going hand and hand with change shop floor management processes and technology, called the connected workforce.
What is a Connected Workforce?
A connected workforce is a team that has access to real-time information, enabling them to communicate better, make better informed decisions more quickly, and alert those in charge of potential problems sooner. It integrates the workers into the entire process of the operation, as opposed to just performing the line tasks. In the context of the supply chain, this means that there is now a connected loop participating in building a more adaptive supply chain; from customers, to distributors, to suppliers, all the way down to the production floor and the people producing the goods. Fortunately, a connected shop floor workforce can help a manufacturing company improve their supply chain in a number of ways.
Real-time Data and Visibility
By connecting workers on the shop floor through digital systems and IoT devices, manufacturers gain real-time visibility into their operations. They can collect data on production processes, inventory levels, machine performance and other relevant metrics. This real-time data allows for better decision-making, enabling manufacturers to identify bottlenecks, optimize production schedules, and respond quickly to changes in demand or supply.
Improved Collaboration and Communication
A connected workforce fosters seamless communication and collaboration among employees, departments and even across different locations. Workers can easily share information, exchange ideas and collaborate on problem-solving. This improved communication facilitates faster response times, reduces errors and enables efficient coordination across the supply chain.
Predictive Maintenance and Reduced Downtime
Connected devices and sensors on the shop floor can provide valuable insights into equipment performance and health. By monitoring machine data, manufacturers can detect potential maintenance issues before they lead to breakdowns or downtime. Predictive maintenance enables proactive repairs, reducing unplanned downtime and improving overall equipment effectiveness. Training the workforce in how these devices work and operate and getting them to recognize potential issues before they occur can help maintenance teams prevent downtimes before they occur.
Improved Inventory Management
With a connected workforce, manufacturers will have better visibility to inventory levels, performance and movements in real-time. Automated systems can trigger alerts for low stock levels, enabling timely replenishment. Accurate inventory data helps manufacturers optimize stock levels, reduce carrying costs, and prevent stock outs or excess inventory. It also enables better demand forecasting and planning.
Continuous Improvement
A connected workforce empowers manufacturers to collect valuable feedback and insights directly from workers on the shop floor. Employees can provide suggestions for process improvements, highlight inefficiencies and report quality issues promptly. This feedback loop facilitates continuous improvement efforts, leading to enhanced productivity, better quality control and ultimately, improved supply chain effectiveness.
Data-driven Decision Making
The connectivity and integration of data from various sources provide a rich dataset for analysis. Manufacturers can leverage advanced analytics and machine learning algorithms to identify patterns, trends and opportunities for optimization. Data-driven decision making helps streamline processes, reduce waste, optimize resource allocation, and enhance overall supply chain performance. Workers on the floor who have access to this data and the understanding of what this information means can be invaluable to an organization.
An Untapped Source of Information
The line worker on the shop floor is the beginning of making a supply chain work once the necessary components are in the factory. These workers are trusted with the most expensive assets the company owns; the equipment and inventory. They see the process everyday and could be valuable sources of information on how to avoid the common repeated problems if they had a means to voice their opinions, concerns and suggestions. Implementing a process and the tools to get the workforce connected to the collaboration process of the organization will open up amazing opportunities for increased productivity and profitability.
Employee Retention
One of the biggest issues manufacturers are facing today is employee turnover; especially with shop floor workers. Hiring and retaining manufacturing line workers has never been more difficult. Empowering the workers on the line to help make a difference in the organization is a critical component to keeping employees on board. Most people need to work, that is a given. However, being a valued member of a team and having the ability to help make a difference in the success of the organization sometimes has more value than the paycheck itself. It is about doing something productive with their day. The processes and tools to connect the workforce is empowering line workers to make a difference.
Is Connecting Your Shop Floor Workforce Worth the Investment?
Here is the bottom line: a connected workforce on the shop floor brings transparency, agility and efficiency to manufacturing operations. By leveraging real-time data, effective collaboration, and advanced analytics, manufacturers can optimize their supply chain, enhance customer satisfaction and gain a competitive edge in the market. If you want to be an adaptive and agile organization, start with connecting your front line workers with shop floor management software and automation systems. The results just might amaze you.
