Continuous improvement plan in manufacturing companies

Manufacturing companies are of wide relevance for the economic growth of a country, so new ways to optimize processes in operations, such as the incorporation of technologies or more complex systems, must always be sought.

To detect the needs or changes that are required, it is key to have a continuous improvement plan, which allows to stand out from the competition and achieve sustainable economic development over time.

So here we will talk about what a continuous improvement plan is and why it is so important in the manufacturing sector.

What is a continuous improvement plan?

A continuous improvement plan is a method that allows companies to analyze, review and adapt the different processes carried out within the production chain.

It should establish everything that an organization has to do to constantly evolve and optimize its performance, in order to obtain better results and be more competitive.  

Importance of having a continuous improvement plan

Being able to optimize a company's processes is the best way to have satisfied customers. In this sense, having a continuous improvement plan and focusing on achieving better products will satisfy their needs and improve the customer's shopping experience.

It is a tool that allows organizations to innovate constantly and without a plan, problems can occur more often, having more inefficient resolutions.

With a continuous improvement plan it is possible to:

• Decrease production time.
• Improve productivity.
• Offer a better quality product or service.
• Optimize the use of available resources.
• Minimize errors.

How to make a continuous improvement plan in manufacturing

To make a continuous improvement plan in manufacturing, you have to follow some steps and consider different elements, which we explain below:

1. Analyze the current situation

Knowing the results of the current processes is key to know what is being done well and what is not, and that is only possible through accurate documentation, which establishes how each activity and operation is carried out within the organization.

2. Define objectives

After having this clear, you have to define what you want to achieve and direct the continuous improvement plan towards them.

Keep in mind that improving the performance of your manufacturing company will depend on the corrections you make and how much you optimize the processes that could be affecting the results of each task. 

3. Compare results between processes

Having the historical information of the company's processes, it is very important to make comparisons between results.

This involves identifying market opportunities, keeping abreast of challenges to adapt production strategies, and knowing what technological capabilities are available and how they can be applied to improve manufacturing processes.

The objective is to be able to find and identify which situations and moments have been most beneficial within the different processes being carried out. 

Identifying and eliminating unnecessary or redundant processes is key to optimizing resources and reducing production costs. 

4. Simplify processes 

A continuous improvement plan in manufacturing companies should not only seek to solve problems, but also to simplify them, in order to increase productivity and reduce costs and time.

Therefore, it is important to generate an active supervision model, through which the performance of each machine or what is used for production can be monitored.

Likewise, control systems must be defined and automation and data analysis technologies must be used to monitor and manage manufacturing processes in real time.

This includes quality management software systems to ensure consistency and accuracy in production. 

Remember to review the results and the process from time to time, taking into account aspects such as productivity, costs and quality to identify areas for improvement through data analysis and feedback from those involved.

5. Implement a maintenance plan

To achieve all of the above and really optimize processes and reduce time and costs, you have to choose to create a maintenance plan.

This will help ensure that you get the best performance from your machinery, and it has to be done by means of advanced maintenance strategies, reducing downtime and improving operational efficiency. 

6. Involve the work team

For an effective optimization of each process, it is essential that the employees involved contribute and are taken into account, because they have to know the new technologies and methodologies to be used. 

Implementing digital platforms for operations requires not only investment in technology, but also in staff training. 

7. Ensures good quality control

For quality control, you have to opt for alert systems that can detect quality deviations during each stage of the production process to ensure consistency and meet customer expectations.

In this way, it will be easier to define the standard times for each action, the frequency and amount of analysis for its execution, control and follow-up. It is also important to perform quality audits on a regular basis to promote excellence in product quality. 

With this, great results can be achieved and the reprocessing time and the amount of rejections due to non-compliance with regulations can be reduced. 

8. Periodically evaluate the continuous improvement plan

When the plan is defined and in place, you have to evaluate the results from time to time, in order to know if it is going the right way or if optimizations have to be made again and thus maintain good processes within the company.

This makes it easier to detect failures, anticipate more serious errors and implement solutions according to the needs of your organization.

Optimize your processes with London Consulting Group

While it is important for companies to have solid capabilities and processes, consulting can bring a lot of value from perspectives and solutions that complement the actions to obtain extra benefits. 

In this aspect, at London Consulting Group, we have experts in the manufacturing field, who can help your company to have a clearer vision of its current situation, detect improvements, achieve a more effective collaboration and make a successful implementation of improvements and strategies. 

With the right tools, training and guidance, you can get the results you are looking for.