Integrated Polytechnic Regional College

Department: Mechanical Engineering

Option: Manufacturing Technology

Module Name: MANUFACTURING PROCESSES

Date: March 07,2024

Manufacturing workflow
A manufacturing workflow is a set of processes that guide equipment and personnel work
from start to finish.
What is the purpose of a workflow?
The purpose of a workflow is to lay the work out clearly for employees so they can
complete jobs efficiently. A carefully planned and detailed workflow will improve the
efficiency of business processes. It also ensures all team members are on the same page.
Types of Manufacturing Workflows
The manufacturing workflow can be categorized into two types:
 The first type of manufacturing workflow is the “push” model. In this model, when
an order comes in, the production team has to work through it quickly. This type of
workflow is used by many companies in their day-to-day operations. However if not
used correctly, this model can be a little challenging to see if all the orders are being
processed properly.
 The second type of manufacturing workflow is called the “pull” model. This is
because customers request work from a set of resources (for example, designers)
who then produce something based on those instructions and send it back out again.
This allows both parties involved with each transaction (the customer/client and
supplier/manufacturer) greater control over how things go together. Even if every
order is processed automatically on autopilot without any input from anyone else at
all.
Classes of Manufacturing Workflows
1. Sequential Workflow: linear workflow, always occurs in a specific order since each
step depends on the successful completion of the one prior. These are particularly
common where quality and safety standards are a concern.
2. Parallel Workflow: In this class of workflow, tasks can occur at the same time to
shorten production time. If components can be created individually, this is most
appropriate.
3. Batch Workflow: Batch workflows involve grouping similar tasks or products
together and processing them as a batch. When production in bulk is possible, it allows
the manufacturer to streamline resources.
4. Agile Workflow: These are typically flexible and adaptable, used in industries
requiring customization. They allow users to make quick adjustments and iterations
throughout the manufacturing process, allowing companies to stay competitive in
dynamic markets.
5. Continuous Workflow: Continuous is non-stop workflow that eliminates downtime or
interruptions, provided equipment is operating properly. This type is common in
chemical plants and steel mills.

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Five main steps of manufacturing workflow
a. Planning: Setting goals, defining tasks, and allocating resources.
b. Organizing: Structuring tasks, roles, and responsibilities.
c. Execution: Carrying out the tasks and monitoring progress.
d. Controlling: Evaluating performance, adjusting plans, and ensuring quality.
e. Improving: Identifying bottlenecks, implementing process enhancements, and seeking
continuous improvement.
Benefits of Manufacturing Workflow
Manufacturing workflow is designed for use in any type of industry, including electronics
or pharmaceuticals, where there are complex supply chains with many suppliers involved
in producing one item from start to finish (or vice versa). The key benefits include the
following:
 Improved efficiency – Manufacturers can optimize their operations by tracking
critical information such as inventory levels across divisions within companies; this
helps them avoid spending excess money on materials while also improving
customer satisfaction, which drives increased sales revenue over time.
 Reduced risks – Using advanced analytics techniques such as machine learning
algorithms allows businesses to make better decisions based on real-time data
rather than relying solely on historical information, which may not always be
accurate due to its limited scope.
 Increased profitability – By automating processes related specifically toward
achieving high-performance outcomes like increased production rates while
simultaneously reducing costs associated with labour shortages due to lack thereof.
How do inefficient manufacturing workflows impact businesses?
Here are some of the common problem statements that occur because of inefficient
manufacturing workflows.
1. Quality control issues
A manufacturer can lose up to 20% of revenue due to quality issues. When
processes are not properly structured or monitored, it becomes challenging to
maintain consistent quality standards. This can result in a higher rate of defects,
increase costs owing to reworks, and potential damage to the company’s
reputation.
2. Resource Allocation Problems
Inefficient workflows can cause the overutilization or underutilization of some
resources. For instance, some machines may be overworked, leading to
breakdowns and maintenance costs, while others sit idle, wasting valuable
resources. This misallocation can strain budgets and hinder overall productivity.

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 3. Lack of agility
When workflows are rigid and resistant to change, it can be challenging to introduce
new products or modify existing ones quickly. This lack of agility can result in
missed opportunities and revenue loss.
4. Employee frustration and burnout
Inefficient workflows can lead to employee frustration and burnout. Workers may
find themselves constantly dealing with bottlenecks, delays, and repetitive tasks.
Over time, this can erode morale and reduce productivity, ultimately affecting the
company’s bottom line and employee retention rates.
But what causes the inefficiency in manufacturing workflows in the first place? Let’s
discuss that.
Factors that lead to inefficient manufacturing workflows?
Here are the top three reasons for inefficient workflows in manufacturing:
1. Lack of standardization: When each team or shift follows its own set of
procedures, it can lead to confusion, inconsistency, and inefficiency. Standardization
ensures that everyone is on the same page, reducing errors, and speeding up
production.
2. Inadequate training: If the employees are not adequately trained, they may not
fully understand the best practices and nuances of their tasks. This can lead to
mistakes and slower processes. Comprehensive training programs are essential to
ensure that all employees have the skills and knowledge needed to perform their
roles efficiently.
3. Poor communication: Inefficient workflows can result from poor communication
between different departments or teams within a manufacturing facility. If the
information doesn’t flow smoothly between production, logistics, quality control,
and other units, it can lead to delays and missed opportunities. Effective
communication can increase productivity by 25%! Thus, it is crucial for streamlining
workflows and maximizing efficiency.

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7 ways to build efficient manufacturing workflows
Here are seven ways to improve the efficiency of your manufacturing workflows to
increase productivity and ensure continuous growth.

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1. Analyze existing workflows
Take a close look at your current manufacturing workflows with a critical eye.

Example:
Through workflow analysis, we know that the process of testing and approving new drug
formulations is unnecessarily complex and time-consuming. By re-evaluating and
simplifying this workflow, you can significantly reduce the time it takes to bring new
medications to market, ultimately increasing your productivity and revenue.
2. Digitization of workflows
Embrace technology by digitizing your manufacturing workflows. Implementing digital
tools and software like a CRM, supply chain management, or MES solutions allows you
to automate workflows and track progress in real-time to make data driven decisions.
Example:
By implementing a digital manufacturing execution system (MES), you can track the
production of each garment in real-time. This system collects data on everything from
fabric cutting to quality control. With this information at your fingertips, you can spot
bottlenecks and make necessary changes in production to improve efficiency.
3. Lean manufacturing principles
Adopt lean manufacturing practices to eliminate waste and streamline processes.
Techniques like 5S {Sort, Set in order, Shine, Standardize, Sustain} and Value Stream
Mapping make your workflows smoother and more efficient.
Here is what 5S are:
1. Sort: In this step, the goal is to separate necessary items from unnecessary ones. It
involves identifying and removing any tools, materials, or equipment that are not
essential for the current work process.
2. Set in Order: Once you’ve sorted the essential items, the next step is to arrange
them systematically. This involves designing a logical and efficient layout for tools,
equipment, and materials so that they are easily accessible when needed.
3. Shine: The shine step focuses on cleanliness and maintaining a tidy workplace. It
includes regular cleaning and inspection of tools, machinery, and the workspace to
ensure everything is in good working condition.
4. Standardize: Standardization involves establishing consistent procedures and
practices for maintaining the first three S’s (Sort, Set in Order, Shine). It involves
creating documented processes and checklists to ensure that the workplace remains
organized, clean, and efficient over time.

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 5. Sustain: The final step, sustain, focuses on maintaining the improvements made
through the previous four S’s. It involves ongoing training, regular audits, and a
commitment to continuously improving the workplace.
Together, the 5S principles aim to create a workplace that is not only more organized and
efficient but also safer and more conducive to productivity.

Example:
For this let’s take the example of a furniture production workshop. Applying lean
principles, you decide to organize the workspace using the 5S methodology. This involves
decluttering workstations, organizing tools, maintaining cleanliness, and standardizing
procedures. As a result, your team can find tools and materials quickly, reduce setup times,
and improve overall workflow efficiency.
4. Employee training and skill development
Invest in training and upskilling your workforce. Knowledgeable and skilled employees can
perform their tasks more efficiently, reducing the chances of errors and improving the
overall workflow. Well-trained teams can also adapt to changing production demands more
effectively.
Example:
In an electronics manufacturing facility, investing in employee training pays off. You can
provide specialized training to your assembly technicians in soldering techniques and
equipment usage. With improved skills, they can solder components more accurately,
leading to fewer defects and rework.
5. Quality control and continuous improvement
Implement rigorous quality control measures at various stages of your workflow to catch
defects early, prevent rework, and reduce production delays. Additionally, establish a
culture of continuous improvement, where employees are encouraged to suggest and
implement workflow enhancements.
Example:
Suppose you operate a food processing plant. To maintain high product quality, you
introduce a rigorous quality control system at various production stages. This includes
visual inspections and taste tests. Feedback from these checks is used to make immediate
adjustments to the process, preventing defective products from reaching consumers.
6. Supply chain optimization
Streamline your supply chain to ensure that materials and components arrive just in time
for production. This reduces excess inventory, minimizes storage costs, and keeps your
workflow running smoothly without interruptions caused by material shortages or
overstocking.

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Example:
If you manage a toy manufacturing company, optimizing your supply chain can work
wonders. By establishing just-in-time inventory practices with key suppliers, you ensure
that the necessary raw materials and components arrive precisely when needed. So, it is
not just about adapting the tech or process, but also improving supplier relationship
management.
7. Data tracking and analysis
Implement a robust data tracking and analysis system. Collect and analyze data from every
stage of production, from component assembly to quality control checks, to identify
patterns and trends.
Example:
Let’s say you start tracking product quality of all suppliers and generate a report regularly.
Now you can easily notice if a specific supplier consistently delivers faulty components.
Armed with this information, you can take corrective actions such as switching suppliers or
tightening quality control measures. This helps you to improve product quality and reduce
costs associated with defects.

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