Food industries in India have seen tremendous growth over the years. However certain elements in the basic structure of these industries have remained to be invariable with time. Despite the up surging developments seen in technology, especially in the pitch of automation, most of the food manufacturing industries in India are still semi-automatic or manual operating entities for diverse reasons. The biggest spot of concern is that the productivity in these entities are lesser than 60 % efficiency. The most common and illustrious golden directive guideline of production states that lesser efficiency of any production unit proportionately increases the manufacturing cost. This has greater consequences and the magnitude of the problem is not so negligible. It remains to be the key reason for the inability of small industries to compete with big giants. In the quest to find a solution to the problem, most of them look at the sky above and wait for the white feather to fall. But actually, the angel resides within the premises. Yes, the solution lies within the industry. By rectifying few common mistake, the problem can be repaired.
- Lack of Production planning system
Unplanned production is like driving a vehicle without knowing the destination. Most food industries are victims to this mistake and tolls naively in terms of wastage due to underutilization of resources such as manpower, time, raw material, machineries and the like which results in quality complaints, higher over heads, huge initial investments, less competitive edge in the product, loosing market due to late deliveries and so on.
Hence, such industrial resources have to be organized against market demands. Performance management has to be reviewed once a month to calculate the efficiency of the output with respect to the existing facilities. Inward and outward ratios have to be evaluated for the continuous flow of production against an order. By monitoring all this, one can at first identify the area where
- leakage of funds with excessive manpower with lower productivity
- immobilized stock of raw material or finished products are in higher ratios
- machineries are underutilized than estimated
- time of the production is not planned properly to take out the desired capacity every day
Hence, the mantra to start your rectification magic is simple. Identify the areas where measures have to be taken and take the adequate control measures in those areas of concern. Then, the overall efficiency increases gradually like the snowballing effect.
- Improper process line
Not having a proper material flow in the manufacturing line is again one those miscue shots hit by many. There should be simple material delivery routes and pathways throughout the facility that connects the processes. Also, there needs to be enough space for flexibility and changes, since volumes and demand are variable over time.
Sometimes there may be one or more machine in a manufacturing line which will not match with the entire manufacturing lines capacity. This could result in poor output and have consequences on the efficiency as well. Hence, as follow the basic thumb rule – “All the machineries involved in a manufacturing line must be synchronous to each other capacities”.
- Lack of training
Another common mistake that ruins the production plans just in time is lack of training. This mistake, in particular, could lead to ultimate loss of resources by accumulation of work in progress, frequent reworks, more rejection and so on. Hence, adequate care must be taken to ensure that a complete training program is conducted before recruiting a person into the manufacturing line. Also, there should be enough trained workers to run the production under all possible circumstances. Proper training is a necessity and experience could come in handy.
Thus, one need not build castles in Spain to overcome the difficulties. It is the aid of few pragmatic and useful measures like these that help in crossing hurdles. Hence, by adopting few practices like these, machine efficiency in industries can be increased to a great extent. Though the industrial machinery which are existent in the present scenario may not be the newest in the business, with flawless production techniques and proper rectification steps to cure existing problems with machines, the cost incurred in production can be greatly reduced. This in turn, increases the margin of profit – the ultimate aspiration of every entrepreneur.