How to Increase Productivity in Manufacturing with Your Existing Workforce

The question of how to increase productivity can be a tough one, especially when there is fierce competition for skilled labor.  In the current market, retaining skilled labor is equally essential, especially in the face of increasing labor shortages and rising turnover rates. It’s no big secret to anyone that satisfied employees are far more likely to remain loyal and productive, while unhappy ones tend to leave. In fact, studies show that nearly 63% of workers leave their jobs due to poor engagement or lack of fulfillment, costing companies an average of 33% of the departing employee’s annual salary to replace them.

For manufacturing businesses with high turnover rates, these costs are no joke, and can quickly add up, impacting both morale and overall productivity. Additionally, happy workers are not only more productive but also serve as a stabilizing force in their workplaces. This reduces the need for constant hiring and retraining.  Just think of how it felt the last time someone you really enjoyed working with moved on to greener pastures.

Beyond the cost of turnover, manufacturing faces unique challenges due to the shortage of skilled labor. The National Association of Manufacturers (NAM) predicts that the U.S. manufacturing sector could face a shortfall of 2.1 million skilled workers by 2030. As a result, it is absolutely vital that business owners focus on getting the most out of their current workforce, requiring them to strike a balance to increase productivity without overburdening employees. One way to do this is by reducing repetitive, mundane tasks that consume time and drain morale. By using software like PrismHQ and other process automation, businesses can allow their workforce to focus on high-value activities that engage their skills and expertise. This week we explore seven ways to boost productivity using your existing team by strategically implementing automation.

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1. Automate Data Entry Processes

Data entry is one of the most repetitive and time-consuming tasks that workers can face. In a manufacturing environment, data entry can involve tracking inventory, logging production data, and maintaining equipment maintenance records. Manual data entry can be error-prone and often leads to wasted time correcting mistakes.

A sure-fire way to increase productivity is by implementing automated data capture software that integrates well with your current systems to save substantial time and increase accuracy. By freeing employees from manual data entry, they can focus on analysis or other higher value tasks.

When implemented thoughtfully, automation can reduce data entry time by up to 80%, and businesses see an average productivity improvement of 20-30% after implementing automated data solutions. This also leads to a 15% increase in job satisfaction as workers spend less time on mundane tasks and more time using their unique skill sets.

Related:  Top 5 Risks of Manual Data Entry in the Manufacturing Industry

2. Implement Digital Workflow Management

Paper-based workflows are not only slow but are also prone to bottlenecks, with forms or approvals waiting on a single person or getting lost in transition. Paper processes add unnecessary delays, especially when coordinating work between departments.

Switching to digital workflow management systems streamlines processes, can increase productivity, and allows employees to track and manage workflows in real time. This software provides visibility into production, inventory, and quality assurance processes, reducing bottlenecks and improving communication across teams.

Manufacturing businesses see an average of a 15% boost in productivity by adopting digital workflows, with a 40% reduction in delays due to improved tracking and visibility. Employees also experience a 12% improvement in job satisfaction by reducing wait times and minimizing miscommunications.

3. Automate Routine Quality Control

Quality control is essential, but repetitive inspections can lead to worker fatigue, which increases the likelihood of errors and defects. Human error is a common cause of product defects, costing the U.S. economy up to $37 billion annually in manufacturing.

Automated quality control systems, such as machine vision and AI-driven inspection tools, can handle much of the repetitive inspection work, identifying defects faster and with greater accuracy.

Businesses that integrate automated quality control systems experience a 20% improvement in defect detection rates and a 10% reduction in waste, translating into an overall productivity boost of 25% in quality control tasks. Moreover, workers gain increased job satisfaction by focusing on higher-level quality analysis rather than mundane inspection tasks.

4. Schedule Predictive Maintenance

Reactive maintenance often disrupts production, leading to unexpected downtime. Maintenance teams are frequently called to repair machines, and routine maintenance can become a drain on valuable labor resources when performed too frequently.

By using predictive maintenance software, you can schedule maintenance based on equipment usage and condition, ensuring repairs are made only when necessary. This proactive approach minimizes downtime while making better use of maintenance staff and increases productivity.

Predictive maintenance has been shown to reduce downtime by up to 30%, increasing productivity by as much as 15%. Additionally, it leads to a 20% improvement in job satisfaction among maintenance teams who spend less time putting out fires and more time on proactive tasks.

5. Automate Inventory Management

Tracking inventory manually or through spreadsheets can be tedious and prone to error. Inventory mismanagement can lead to production delays, overstock, and other costly issues.

With automated inventory management software, businesses can track inventory levels in real time, set reorder thresholds, and even integrate with suppliers for automatic ordering. This reduces errors and ensures the right materials are available when needed.

Companies that implement inventory management automation see a 30% reduction in inventory errors and increase productivity by 25%. This also reduces employee frustration with stockouts and overstock situations, leading to a 10% boost in job satisfaction.

6. Streamline Training with E-Learning

Traditional training can take weeks and consume valuable time, keeping employees away from their core tasks. When new equipment or processes are introduced, repetitive in-person training sessions can slow down the onboarding process.

E-learning platforms tailored to manufacturing processes allow employees to learn at their own pace, accessing training materials on-demand. Modules can cover everything from safety protocols to machine operations, reducing the need for constant retraining.

E-learning can reduce training time by up to 60% while boosting knowledge retention by 30%. Employees feel more confident and prepared, resulting in a 20% improvement in job satisfaction.

7. Introduce Collaborative Robotics (Cobots)

Certain manual tasks, such as assembly or sorting, can be time-consuming and are repetitive in nature. Workers who perform these tasks may experience decreased engagement and productivity due to fatigue.

Collaborative robots, or cobots, can take on repetitive tasks such as assembly or material handling, working alongside humans safely. Generally, they are easy to program and can be quickly adapted for different tasks, allowing your workers to focus on higher-value activities.

Cobots can increase productivity by 50-70% in tasks where they are applied, while businesses typically see a 30% improvement in job satisfaction from workers freed from repetitive labor. Cobots can also reduce turnover rates by up to 15% by enhancing job roles and decreasing physical strain on employees.

Final Thoughts

In a time of skilled labor shortages and rising employee expectations, leveraging automation and technology is key to increasing productivity and retaining talent. By automating repetitive, mundane tasks, manufacturing companies can help employees focus on more valuable work, improve job satisfaction, and ultimately drive better business outcomes. With the right technology and a focus on employee well-being, manufacturing businesses can thrive even amidst labor shortages, creating a more sustainable and efficient workplace.

We Can Help

If you’re ready to take the first steps towards a faster and easier way to manage your business, PrismHQ provides a simple and flexible solution to streamline production, increase visibility, and improve communication across departments. Our mission is to serve growing manufacturers by providing a single, affordable solution that automates inventory management and integrates it with daily business processes for increased productivity and lower overhead. Contact us today to learn more!