The biggest challenges facing manufacturers in 2022 – and how to overcome them
The end of the year is usually a time to reflect on the last twelve months. For manufacturers, 2021 continued the same themes from 2020 as a trying time, primarily due to the coronavirus pandemic, though many started their recovery with record levels of orders.
Brexit also took place at the end of 2020, bringing new hurdles. Even with lockdown restrictions gone in the UK, the combined effect of the pandemic and Brexit has led to continued difficulty for manufacturers in the form of skills shortages and supply chain disruption.
While we take stock of the year, it’s also an opportunity to look ahead to 2022 and ask what manufacturing may look like then compared to now, especially given the current issues in the industry. By doing so, plants can prepare for the obstacles coming in the next 12 months and adapt.
Below, we have listed the top five challenges facing manufacturers in 2022, including what can be done to effectively address the issues and achieve your best outcomes.
Net-zero
Following the COP26 in November, it is clear that reducing the UK’s environmental impact is a significant target for the government. As part of the climate commitments detailed at the conference, the Chancellor of the Exchequer confirmed firms would be required to release their net-zero plans by 2023.
This highlights the increased emphasis on all businesses, including manufacturers, to lower their eco-footprint. As such, plants will be expected to review their impact on the environment and develop an approach to meet the UK’s net-zero goals.
There are many ways plants can introduce green targets into their operations and lessen their environmental impact. Examples include utilising renewable energy, using recyclable or eco-friendly supplies where possible, disposing of waste correctly and installing equipment with reduced power consumption.
Another critical factor in reducing your plant’s environmental impact is finding efficient solutions. This includes machinery that reduces product giveaway (thereby reducing waste) or optimises your production line so that less is lost through unfit output or the need to reprocess lines.
If you seek equipment that helps you with your sustainability goals, it’s worth working with an environmentally conscious partner who can determine and provide the tools you need to meet your production requirements while limiting your carbon footprint.
Supply chain disruption
Supply chain disruption is one of the issues currently causing the most difficulty in the manufacturing industry, and it is predicted to continue into 2022. While manufacturers have little control over supply chains, they can take steps to strengthen their position until the crisis comes to an end.
Start by comparing suppliers to ensure the ones you work with are still offering the best service. While similar issues will hit most suppliers, there may be varying stock availability – meaning if your usual provider cannot help you, another may have the materials you need. It’s therefore worth speaking to various suppliers until you find one that most suits your requirements.
The key is to keep in touch with your suppliers to find out about any upcoming shortages or disruptions ahead of time. This allows you to stay ahead of the game and adjust your production schedules accordingly whilst focusing on the output you can create.
Once more, having efficient machinery will help here. By optimising your production lines, you can reduce product giveaway and prevent the risk of wasted raw materials due to processing errors. This will enable more of your supplies to be turned into quality output used to fulfil order levels rather than contribute towards waste.
The skills gap
Another crucial barrier currently facing the industry is the growing skills gap. A report earlier this year found engineering and manufacturing were feeling the worst of the skills shortage, with 85% of businesses being affected.
While manufacturers need to adapt their recruitment strategy where possible to continue to attract the best talent into their vacancies, there is an increased move to automation in plants to alleviate some of the need for manual labour.
In today’s market, automated equipment can offer the same or higher levels of quality and consistency as more manual options, even for delicate products. They can also provide increased traceability, quality control and worker safety.
If you’re considering automation, it’s essential to find a solution that meets the requirements of your output while maintaining accuracy and reliability. Earlier this year, we launched the TSD-N3, a semi-automatic weigher, which features delicate product handling and high-speed processing. It also reduces the labour requirement by up to 80% while offering an excellent return on investment.
By introducing automation equipment, even on a small scale, you can ease any potential skills gaps or blockages in your business while still maintaining quality across your production lines and meeting your targets.
While it can be time-consuming and an investment to introduced automation in your plant, with the labour shortage predicted to last for a while, it should ease the pressure on your recruitment strategies and bring long-term results.
Use of intelligence
Intelligent manufacturing has been on the rise for the last few years, and, given the problems likely to appear in 2022, now is the time for plants to introduce it into their operations.
The name ‘intelligent manufacturing’ may seem daunting, conjuring up images of AI robots and virtual reality. However, it is much simpler to incorporate intelligence into your production – and doing so can have dramatic results.
One of the easiest ways to welcome intelligence is through data collection and analysis. This allows you to track performance across your production line and understand how effectively your processes are working. Through this, you can identify areas for improvement, including opportunities to reduce waste and costs.
Over time, data analysis will allow you to create the optimal conditions for production, with a minimised risk of downtime, errors or other issues, and consistently high quality across your output.
Solutions like Yamato Stats have been created to enable manufacturers to easily implement data collection into their plants, allowing for 2-way communication between your equipment and will help you to track the efficiency of your plant.
With optimised production, you will also be better placed to meet net-zero targets (through materials and energy only being used to create quality output rather than waste), make the most of supplies and better manage costs. The rewards gained for your plant are extensive – and can help you overcome the other challenges predicted in 2022.
Output quality
No matter the outlying circumstances, quality will always win. Following the pandemic, consumer expectations are higher than ever, with a particular emphasis on hygiene. Regardless of any obstacles your plant may face, your priority must be to meet these expectations and provide the best quality.
Several factors can drive quality in your plant. With safety and hygiene pressing concerns, it’s essential that you have rigorous quality assurance and control processes, including product inspection. This will allow you to review your output and address any issues, including contamination, before they reach your customers.
It’s also essential to ensure you have compatible machinery for your output, with the right environment, so that materials are processed correctly, and your specifications are met. This will further help to reduce contamination or hygiene issues.
This is, of course, on top of a regular cleaning schedule across your factory and encouraging hygiene compliance among your workforce.
An optimised production line will further boost quality by reducing the risk of incorrect processing or error. To ensure this, performance monitoring and machine maintenance will be vital.
By focusing on quality, you can consistently meet consumer demand and stay on top of their changing behaviours. This will allow you to maintain sales levels, even when circumstances aren’t ideal, and improve your reputation as a manufacturer. Many benefits stem from this compared to providing poor quality – including reduced costs and increased revenue.
Conclusion
Regardless of how 2021 may have gone for your plant, we should all look ahead to 2022 and the opportunities that lie ahead. By understanding the challenges likely to face manufacturers, you can gain insight and adapt for the 12 months to come and put your plant in the best possible position to succeed. This means being open to intelligence, considering the environment, accounting for supply chain disruption and skills gaps, and, most importantly, constantly pushing quality.
At Yamato, we provide a wide selection of intelligent solutions that can empower you to address and overcome challenges in your production. This includes automated machinery, product inspection systems, data monitoring tools and climate-considerate equipment. We can also work with you to identify line solutions tailored to your products and specifications.
Get in touch to find out how to create an effective production line for 2022 that allows you to achieve your best-ever results.