Dealing with changes in manufacturing: 4 false beliefs to avoid

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Globally, change is sweeping across every industry - some industries more than others. For the manufacturing industry, these changes are numerous. How can manufacturers manage this situation on top of everything they have to manage while running their plants? Well, rather than struggling to catch up with these changes, a better approach is to understand what’s coming and prepare well ahead. 

Let’s take a look at some of the widespread changes taking place in manufacturing today. We’ll discuss how manufacturers can prepare ahead and what they can do to dispel some age-old myths and false beliefs that are still affecting the business of manufacturing.

1. Increased technology and robotics

The manufacturing industry faces massive changes due to digitization and technology, especially in the areas of automation and robotics deployment just as critically – leading to a rise in productivity. Manufacturers need to leverage these technologies and prepare for the changes they bring.

False belief: robots will replace people on the plant floor.

Repeatedly, workers in the manufacturing sector have expressed their fears that robotics and automation will take over their jobs. For instance, this survey of 16,000 plant workers by BCG found that more than half of those interviewed expressed concern about the potential threat that automation poses to their source of income. 

Although robotics are playing more roles on the plant floor, industrial workers and their employers are not completely powerless – instead, opinions are highly divided on the human jobs vs automation debate. According to a Pew Research study, while half of those interviewed felt that robotics and other digital agents will displace a significant number of jobs in the blue and white collar category, the other half believe that robotics will eventually create more jobs than they take. This latter viewpoint is also corroborated by Josef Stredula, head of the Czech-Moravian Confederation of Trade Unions.

To tackle this particular change, manufacturers will need to be forward-thinking. They can introduce their workforce to robotics and other digital agents early, and encourage them to undergo further training. For instance, they can encourage their employees to upskill and learn to perform daily tasks alongside collaborative robots. That way, they’re helping their staff to remain relevant well into the future, and creating a win-win situation for all parties.

2. Maintenance is evolving

In manufacturing, traditionally maintenance and production often have a tense relationship. The major issue is the need to shut down critical production equipment for long periods so that maintenance crews can carry out essential maintenance. Sometimes, to avoid affecting production, maintenance is skipped entirely.

Yet, continually overlooking maintenance or postponing it to a more ”convenient time” can result in several negative consequences. 

False belief: maintenance always means downtime and loss of precious production time. 

Fortunately, this friction between production and maintenance can be minimized. Manufacturers can limit these issues by deploying appropriate manufacturing maintenance software. Among other things, this software will enable the different units concerned to collaborate seamlessly to plan and schedule maintenance activities. Thus, the maintenance team can proceed to execute the required repairs at the most opportune times, with minimal impact on production deadlines. 

That said, the most common cause of these kinds of situations is the fact that some critical machinery failed suddenly and needed to be restored promptly. Almost every manufacturer has experienced this kind of sudden breakdown scenario at one point. 

With recent innovations in maintenance, this constraint can be minimized even further through predictive maintenance - a maintenance strategy that empowers maintenance personnel to pinpoint the most ideal time for equipment maintenance.

3.   The manufacturing skill gap will drive recruitment trends

As more and more workers become eligible for retirement and subsequently leave the workforce, the manufacturing skills gap among European plants will continue to grow. Manufacturing companies will need to think out of the box in order to attract, recruit and retain a younger crop of workers. However, these younger workers come with a unique set of expectations and needs. For instance, they want better incentives and perks, and they won’t tolerate an unfriendly or outdated work culture.

False belief: manufacturing is an outdated, tedious and dreary industry.

To attract the new crop of talent, manufacturers will need to strategize and begin to consider work models that were foreign in traditional manufacturing work. Therefore, it’s important to  create a work culture that makes workers want to stay. Also, offering incentives like remote and flexible work options is now a big attraction for the newer generation of workers, largely due to the prevalent desire for a better work-life balance. 

Although remote work in the manufacturing setting is a relatively new concept, it can happen through solutions like remote diagnostics, work management platforms, and collaboration tools.

4. Ethical manufacturing remains relevant

The volume of waste generated by manufacturers across Europe has always been a cause for concern.

For instance, commercial and industrial activities generate millions of tonnes of waste every year in UK alone. Mechanization and automation have boosted manufacturing productivity enormously, and of course, some level of waste is inevitable during manufacturing. 

However, the point here is that this waste can be managed better. Recent events show that consumers are taking note and reacting en masse against manufacturers that operate without due regard to the effects of their operations on the environment.

False belief: faster and cheaper manufacturing is always best.

Final thoughts

Much has been said about change in manufacturing. The fact is, manufacturers must continue to embrace change in order to stay ahead of competitors, and win their market share in this extremely demanding and ever-evolving industry. Achieving that starts with being mindful of the issues discussed above.

- The author Bryan Christiansen is the founder and CEO of Limble CMMS. Limble is a modern, easy-to-use mobile CMMS software that takes the stress and chaos out of maintenance by helping managers organize, automate, and streamline their maintenance operations.

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