Efficiency is a measurable amount of optimal use of labor, energy, or time to accomplish a task or objective. As for efficiency – it is interpreted differently in different contexts.
Technically:
Efficiency describes a high level of performance for an objective or task. Which uses the least number of inputs to get the maximum amount of output.
(1) Economic Efficiency, (2) Machinery, (3) Labor efficiency
In which attention is kept:
- Work with minimal human and mechanical efforts
- Do not spend time during running processes.
- Apply the desired effect with the waste.
- No compromise with quality
- Equipment should be used to the maximum according to its capacity.
- By taking advantage of the skill, it should be used properly in the field.
In simple language, when we require more inputs resources’ quantity than require in processes than usual, it is calls inefficient processes, as same way if we require least number of inputs of resources for processes than usual, it is calling efficient processes.
Usually in manufacturing processes, efficiency can be measured with various metrics, such as:
- Number of units produced per hour.
- The percentage of defective products
- The amount of waste generated during the production process.
Efficiency is very important in manufacturing because it directly impacts on the profitability, competitiveness, and productivity. Simply, more efficient processes mean lower manufacturing costs, and good quality products.
That is why we have to focus on efficiency to increase the overall performance of manufacturing processes.
Tools & techniques
Here are below some techniques that we are going to discuss on it:
| TECHNIQUE | OBJECTIVES | CONCEPTS |
|---|---|---|
| Lean Manufacturing | Reducing waste in the production process. | Continuous improvement, respect for people, elimination of waste. |
| Six Sigma | Reducing defects and variation in the production process. | Data-driven approach, measuring and analyzing data, reducing, or eliminating variation and defects |
| Total Quality Management | Comprehensive approach to quality management. | Customer satisfaction, involvement of all employees, setting quality standards, continuous improvement.. |
| Kanban | Optimizing flow of materials and information. | Visual management, signalling for replenishment, task scheduling. |
| Poka-yoke | Error prevention in production process. | Designing processes/equipment to prevent errors, error detection/correction. |
| Just-in-Time (JIT) | Producing only what is needed, when it is needed, and in the quantities needed. | Reducing waste, optimizing use of resources. |
| Kaizen | Continuous improvement. | Making small, incremental improvements to the production process on a continuous basis. |
| Value Stream Mapping (VSM) | Visualizing the flow of materials and information in the production process. | Identifying areas of waste and inefficiency, improving the flow of value to the customer |
These above lists of techniques are very helpful to improve efficiency in the manufacturing processes. The combination of multiple techniques may give a better result to optimize the production lines much better.
EXAMPLE:
Here we are going to give an example that will help you to understand how the tools and techniques can help to increase the manufacturing process efficiency. As well how efficiency is important for any manufacturing unit.
Suppose Rvl2 is a manufacturing company that produces a wide range of textile products. The business has been operating for over 20 years and has a reputation for producing high-quality products. However, in recent years, the company has been struggling with inefficient manufacturing processes.
Here in, we will describe what exactly factors that affected, and what action plans that Rvl2 require to establish.
What exactly are the details about inefficient manufacturing processes?
Behind the inefficient manufacturing processes, there were several factors. Such as:
- Outdated machinery
- Inadequate training of workmen
- Poor Quality control
The Rvl2 is also facing a shortage of raw materials, as a result delays in manufacturing processing, and increments in costs of processes.
In this example, we will illustrate the inefficiencies in Rvl2’s manufacturing processes. Herein we are going to describe production data of textile products materials for example.
Textile Materials for month of January:
| PRODUCTION STAGE | NUMBER OF UNITS PRODUCED | TOTAL PRODUCTION TIME (HOURS) | AVERAGE TIME PER UNIT (MINUTES) |
|---|---|---|---|
| Cutting | 1000 | 80 | 4 |
| Sewing | 900 | 150 | 10 |
| Finishing | 800 | 120 | 9 |
| Packaging | 700 | 60 | 5 |
| Total | 3400 | 410 | 7.5 |
Here we can observe:
- The Production time for the textile Materials is 410 Hours.
- An average time per unit of 7.6 Minutes.
However, the information does not consider (1) The downtime due to machine breakdowns, (2) Shortages of raw materials, and other inefficiencies.
What implementation action plans require?
To effectively implement the action plans, the Rvl2’s manufacturing processes requires a team of experts. This team will analyze the information to identify the root causes of the inefficiencies.
- The action plans for improve efficiency:
- Upgrading the machinery, equipment and supporting tools.
- Providing training to each workman.
- Improving quality control.
- Ensuring a steady supply of raw materials.
There are also requires implementing proper scheduling system to reduce downtime and improve efficiency.
What techniques are required to use in manufacturing processes?
To implement action plans, the Rvl2 company has taken some techniques to improve the overall processes. Such as lean manufacturing for reducing waste, six sigma, TPM, Kaizen etc.
The company had also implemented – Total productive maintenance system that increase the productivity of machinery by reducing breakdowns and downtime. For improvement – the company had also used kaizen technique that ensured a continuous improvement.
Efficiency Improvement:
Here as below you can see the table is describing the new collection of data for month of June, the information shows in the table is after implementation of action plans. The action plans used various techniques.
| PRODUCTION STAGE | NUMBER OF UNITS PRODUCED | TOTAL PRODUCTION TIME (HOURS) | AVERAGE TIME PER UNIT (MINUTES) |
|---|---|---|---|
| Cutting | 1500 | 50 | 2 |
| Sewing | 1400 | 70 | 3 |
| Finishing | 130 | 60 | 4.6 |
| Packaging | 1200 | 400 | 2 |
| Total | 5400 | 220 | 4.1 |
- We can observe the following things, after implementation:
- The production time for the textile materials has been reduced from 410 hours to 220 hours.
- The average time per unit has decreased significantly from 7.6 minutes to 4.1 minutes.
- The production cost is also may reduce in line with other improvements.
Summary:
In conclusion, a manufacturing company Rvl2 was facing inefficient manufacturing processes, due to old machinery and equipment, lack of training and poor-quality control as well. After the implementation of various tools and techniques, the company received a good amount of improved data after a few months.