How to address and overcome the COVID-19 challenges in your production lines
Since the start of the coronavirus pandemic in March 2020, the whole world has had to overcome unexpected barriers. This is certainly the case for the manufacturing industry, with a reported decline of 4.9% from pre-pandemic levels.
While it is undeniable that many manufacturers will have experienced challenges, what these challenges are will vary from plant to plant. Some factories have reported increased downtime due to halted projects and lost clients, while others (particularly those in the food sector) will have witnessed unprecedented demand. This is all against a backdrop of social distancing and government guidelines, meaning companies cannot facilitate ‘normal’ production.
In response to the pandemic and its consequences, manufacturers have had to be resilient and amenable to change. As we push through a third national lockdown, these values are still crucial to help businesses survive and prepare for the new, post-pandemic normal. This means addressing the unique challenges you are facing.
Below, we have outlined ways to adapt to the impact on your plant, depending on what you are experiencing.
If you are facing high levels of demand
In contrast to manufacturers experiencing reduced demand during the pandemic, some factories may find themselves having to meet their highest output targets ever. Specific sectors, such as retail food, healthcare and technology, have seen demand rocket as consumer behaviour transforms in response to coronavirus and lockdowns.
While these businesses will be enjoying increased revenue, it can be difficult to adjust your production to meet the unexpected need for greater output. It is fundamental to be agile during this time, so that you can scale up production while still accounting for the principles of quality, hygiene and safety.
We have outlined some steps to take that will help you to find the balance.
Find equipment that allows for increased productivity
If you have to expand your operations to meet increased targets, it is vital to have the right tools. Often, this means identifying equipment that will facilitate your productivity.
When seeking equipment for this purpose, take note of aspects like precision, accuracy and speed. You want to find solutions that allow you to work at a high pace, while still delivering high quality and value for money.
You also need to consider what machines are most compatible with your applications, as this will enable them to do the best job and deliver results. Using incompatible solutions could result in low quality, increased wear and tear and possible downtime. So, be considerate of the needs of your products and tailor your equipment accordingly.
If you are looking to speed up production to support higher output, it may be worth considering automation. Automated equipment works with little human input required, leading to increased speed. Modern automation can also be highly accurate, so your results are not compromised. Plus, with social distancing prevalent in workplaces, automated alternatives will reduce the number of staff required at one point, helping to maintain compliance with government guidelines.
A final consideration involves assessing how hygienic your machines are. If you are running at full capacity, you want to leave as little time as possible between batches. This means cleaning equipment quickly while still complying with hygiene regulation. Machines that are high in IP rating (IP67 or above) tend to allow for easy cleaning, so may be preferred if you are processing sticky or liquid products. However, the hygiene implication will vary depending on your applications, so it is vital to consider what works best for you.
Allow for regular cleaning and maintenance
In the pandemic era, there is an emphasis on cleanliness. Therefore, it is in the best interest for companies to ensure they have a robust hygiene culture in their plants, encompassing their staff, equipment, and environment.
Even if you are exceptionally busy, it is crucial to undertake scheduled, regular cleaning. This may include premise-wide cleans, as well as rigid cleaning of equipment and machinery after every use. Ensure you are meeting hygiene standards for your sector as well as COVID-19 guidelines. This will keep your staff and customers safe, helping you avoid customer dissatisfaction, outbreaks, and negative publicity.
Similarly, if you are busy, your machines will be working overtime. This will place increased pressure on them, heightening the chances of damage and breakdown further down the line. In some cases, the need for repair can be a showstopper, which will be unwelcome when you have lofty production targets to hit.
As such, it is essential to continue to regularly maintain your lines to catch faults early on and rectify them. This will help machines to work effectively, so you enjoy continued quality. Regular cleaning will help with this too by minimising product built up on your equipment and preventing damage.
If you are at full capacity, it may be worth utilising a maintenance contract to recruit external resource to carry out your checks.
By scheduling frequent cleaning and maintenance, you will enable your lines to run unimpeded for longer, so you can reach your output goals without compromising quality. While it may mean temporary breaks to your production schedule, the results will be worth the time taken.
Be ready to repair
As we have already touched upon, a breakdown during a busy period can have awful consequences. While care and maintenance of your machines will dramatically reduce the likelihood of a breakdown happening, there may still be occasions when a piece of equipment breaks unexpectedly during the working day. When this happens, you need to act fast to reduce lost downtime and disruption.
Having spares in your factory will aid quicker repair. With the parts you need already at your disposal, you can start the remedial work as soon as a problem emerges, saving precious time.
When sourcing spare parts from your machine supplier, they should provide instructions on how to fit the equipment correctly. This will enable you to carry out the work in-house without having first to call out an engineer. It also minimises visitors to your site, which is critical during the pandemic. Some machine manufacturers may be able to offer contactless support with your repair.
It is imperative to have a stock of the parts you need across your respective machines – so that you have the means to fix machinery no matter what the fault is. Breakdowns will often happen unexpectedly and at the most inconvenient time, so having an adequate spares inventory will ensure you’re always prepared.
If you are facing increased downtime
Many plants have experienced reduced demand during the pandemic, perhaps due to contracts being paused due to government guidelines or customers being conservative in their spending. If this applies to you, your focus should be on what you can do now to aid recovery later.
With less demand, you likely have lower output targets to meet and therefore may have more ‘free’ time within your operations. This is an opportunity to take stock of performance and create conditions that will enable you to operate efficiently. You should also plan ahead for when demand increases, so there are no barriers to your productivity.
Manage your stock
Managing your stock is recommended to make sure you have all the materials you need for your operations. You should have a detailed inventory of everything you need for your production line, so check against this to ensure you have everything you need. This is also an excellent opportunity to clear out your warehouses, such as getting rid of out-of-date products or unwanted items.
If you have a cluttered stock room, use your off-peak period to arrange it properly (such as in expiration date order) to make it easier for staff to source what they need.
Stock management may also apply to your collection of machinery spare parts. Having a healthy inventory of spare parts is recommended in any plant to allow for quick repair when something breaks (which will undoubtedly happen as machines get used over time). By having the relevant, genuine parts ready to install, you can quickly reduce downtime and resume safe, effective production.
So, use the additional time to review what spares you have and what you might need. This will enable you to build up an inventory, so when productivity scales back up, you will be positioned to avoid any unwelcome halts to productivity.
Undertake maintenance
Throughout production, machinery is prone to wear, tear and damage. To ensure equipment is working at an optimal level, it is essential to review your equipment regularly. If you are experiencing downtime and machines are switched off for long periods, it is the perfect time to perform checks and maintenance.
Familiarise yourself with the necessary checks to undertake on your different pieces of machinery. This may include running tests, looking at specific components and monitoring lubricant levels. Part of your maintenance checks may also include a full clean of the premises and equipment, as this can also impact your production lines’ effectiveness.
If you do spot any faults in your machines, seek to repair or replace parts. This will enable systems to continue to work efficiently and prevent the problem from spiralling into a more costly, time-consuming breakdown. It also means that once production ramps up again, your production line will be working at optimum levels, with reduced product giveaway, contamination and downtime.
If you do not have a trained person in-house to carry out maintenance, it’s worth employing external resource to do this for you. Maintenance contracts will equip you with skilled engineers who can carry out regular maintenance for you, ensuring your production line is working at all times. It’s worth calling your chosen equipment supplier to check if they are still doing site visits, as many will be in a COVID-safe way.
Review operational performance
Having quieter periods within your factory gives you ample opportunity to review your operational performance to date and determine where improvements could be made. Start by looking at any data you may have and assess where your weaknesses and strengths lie.
If you find any gaps within your operations, consider what could fill them. Do you need new equipment to fulfil new purposes? Do you need better equipment that helps you to reach your objectives? Or is there a way your production lines could be adjusted to offer a better result? By asking these questions, you will be well placed to uncover the solutions to your problems.
Identifying any need for new equipment or changes to your lines is best to do when you have increased downtime. If you need to install or move machinery, this will give you the time and space to do it without drastically impacting your production schedule. It’s also a great time to implement any new projects upcoming within your plant.
By seizing the chance to review your operations, you will maximise its efficiency and create conditions that allow optimal results. This will be welcome as part of your post-pandemic recovery once demand ramps up, enabling you to meet output goals and deliver quality.
Summary
There is little manufacturers can do to control a global pandemic. However, what they can control is how they rise to the challenge presented to them during this time.
Whether you are experiencing high levels of demand or the polar opposite, it is vital to adapt and understand how to make the most of what you have been handed. For those facing downtime, this means forward-planning and preparing your plant for post-pandemic success. For those facing increased output pressure, it means equipping your factory for the workload without losing quality.
Perhaps one of the most essential steps you can take at this time is to utilise available support. We’re all in this together – so, if you can access help to ease the strain on your production, you should.
At Yamato, we are here for you whatever your issue is. We continue to provide services such as technical support, maintenance and supply of spare parts. We’re also able to advise you of the best solutions for your production line to maximise productivity and incorporate new objectives into your operations.
To find out more, please get in touch with a member of our team today.