How to Achieve Operational Excellence in Manufacturing

In the high-stakes world of hardware manufacturing, the difference between success and failure hinges on the slimmest of margins. Engineers are all too familiar with the daily challenges of optimizing production lines, ensuring product quality, and meeting tight deadlines. Operational excellence is the North Star in this complex landscape, promising not only enhanced efficiency and reduced costs but also a competitive edge.

At First Resonance, we understand the complex hurdles you face and the critical impact of operational decisions on your business's success. Consider this blog your blueprint for transforming the ideal of operational excellence in manufacturing into a practical, actionable reality within your factory's walls.

Join us on this journey to redefine the boundaries of what your manufacturing operations can achieve.

Pillars of Operational Excellence in Manufacturing

The experts at IBM provide a comprehensive definition of operational excellence:

“Operational excellence (OpEx) is an approach to business management that emphasizes continuous improvement across all aspects of the business and within all business processes by creating a culture where management and employees are invested in business outcomes and empowered to implement change.”

In other words, it’s an approach that integrates problem-solving and leadership as a means to drive continuous improvement. Essentially, this creates a proactive culture that stays one step ahead of problems to gain a competitive edge.

When it comes to operational excellence in manufacturing, it transcends mere efficiency. Ops excellence encompasses the relentless pursuit of eliminating waste, enhancing product quality, and ensuring the optimal use of resources at your factory.

Achieving operational excellence requires a structured approach that is built upon several foundational pillars:

• Culture of Continuous Improvement: Culture is at the core of any operational excellence strategy. The goal is cultivating a workplace culture where every employee is engaged in the process of identifying and implementing improvements.
• Process Optimization: A systematic review and optimization of manufacturing processes can effectively help eliminate waste, reduce cycle times, and improve quality. Overall, this can help improve production efficiency.
• Technology and Innovation: Don’t let legacy technology hold your factory back. The adoption of Industry 4.0 technologies such as IoT (Internet of Things), AI (Artificial Intelligence), and advanced analytics is a good place to start.
• Leadership and Strategy: Visionary leadership is not only necessary for the execution of ops excellence but also for inspiration. They play an important role in guiding their teams through the transformation process.
• Customer Focus: Finally, it’s important to align operations with customer needs and expectations. Keep feedback in mind to help with continuous improvement processes.

Operational KPIs to Consider

According to Oracle, operational key performance indicators (KPIs) show how well a company executes its day-to-day work. There are numerous KPIs to choose from, but not all of them are relevant for every industry.

Here are just a handful of essential KPIs that hardware manufacturers can use to gauge their operational excellence:

• Overall Equipment Effectiveness (OEE): A comprehensive metric that measures how effectively manufacturing equipment is utilized.
• Cycle Time: Measures the total time from the beginning to the end of a manufacturing process.
• Yield Rate: The percentage of products that meet quality standards without requiring rework.
• Downtime: The amount of time production was halted due to equipment failures, shortages, or other inefficiencies.
• Inventory Turnover: How often inventory is sold and replaced over a specific period.

These are just a few operational KPIs, others include customer satisfaction and employee turnover. It’s always important to look at the full picture of your factory – people and processes included – on your journey to ops excellence.

Operational Excellence Example in Manufacturing

Want to see operational excellence in action?

The case study of VAST showcases how advanced technology can streamline processes, enhance efficiency, and control costs. By integrating ION software, VAST achieved significant improvements in real-time data capture, process tracking, and quality control, leading to reduced operational costs and higher customer satisfaction.

Learn more about how VAST utilized advanced technologies and strategies for continuous improvement.

Building an Operational Excellence Strategy

With all of this in mind, you’re probably wondering how you can implement an operational excellence strategy to give your factory a competitive edge. Ultimately, this requires a structured approach that aligns with your overarching goals.

1. Define Goals: Define your vision for operational excellence and how it will help the objective of your organization. Establish measurable goals you hope to achieve from ops excellence, such as cost savings or improved efficiency.
2. Assess Your Operations: Analyze your existing processes and look for areas of improvement. This can further help you set realistic goals.
3. Develop a Plan: Create a detailed plan of action needed to achieve ops excellence. It can include optimizing processes and new technologies.
4. Engage Employees: Since operational excellence is all about culture, you need your people on board. Align team objectives with your goals and communicate your vision to your team.
5. Implement and Monitor: Now, it’s time to execute your strategy. Keep operational KPIs in mind to monitor your progress. Make changes as needed based on real-time data and employee feedback.
6. Continuous Improvement: Operational excellence in manufacturing is an ongoing process. Regularly review processes and learn from setbacks to cultivate a culture of continuous improvement.

Learn more about how ION from First Resonance can help your hardware manufacturing operation achieve a competitive edge.