Optimizing Pallet Manufacturing Workflows

There is more to efficiency than having more products, faster. Efficiency also refers to reducing product damage, improving space utilization, and handling materials smartly. Do you know how to optimize pallet manufacturing workflows for efficiency? Could you implement it at your facility today? We have some ideas.

Mapping Your Pallet Manufacturing Workflow and Its Bottlenecks

Think through your company’s production processes. Examples include:

• Pallet design.
• Materials cutting.
• Manual or machine-aided assembly.
• Subsequent quality checks.

Next, determine the key players in the workflow metric. Frequently, these include machine operators, members of logistics teams, and quality control technicians. Depending on your operation, there may be additional players. As in any facility where multiple key players operate, you are likely to have workflow bottlenecks. Identify and trace them to a department, manufacturing step, or key player.

Identifying Workflow Inefficiencies by Dissecting Bottlenecks

You have pinpointed areas where your workflow is underperforming. Do not rely solely on a one-day observation. Once you have noted the problems in your workflow, review data to assess the duration of inefficiencies and their outcomes. Examples include downtime, rework rates, and poor labor utilization. Remember to check for machine idle times if you have invested in machinery. Check off the steps of the pallet assembly line for best results.

Finding and Implementing Strategies for Workflow Optimization

You know where the problems are, and you also know the key players who make a difference in your operation. Now is the time to consider optimizing pallet manufacturing workflows for efficiency.

Improve Material Handling

Optimize and standardize inbound and outbound material movement. The fewer people who handle materials, the faster the items move. Now is also the time to consider smart inventory systems and optimizing your warehouse's layout. Ask employees for input to address pain points in the production process.

Explore Lean Manufacturing Principles

The goal is to reduce waste in materials, time, and labor. Other companies have had excellent success with implementing 5S for organization and efficiency. These 5S, which come from Japan, encourage manufacturers to:

1. Sort. Get rid of useless steps and machines that add to the length of the workflow but are not essential. You may be surprised to learn that you have added considerable time to the production process with workflow steps that are easily omitted.
2. Set in order. After purging your operation of the non-essential steps, organize what is left.
3. Shine. Keep the work area clean and maintain machines for maximum efficiency.
4. Standardize. Retrain workers as needed to maintain the streamlining of the workflow.
5. Sustain. Encourage key players in your operation to look for ways to further slim operations.

Integrate Automation and Software Applications

Would it surprise you to learn that many competitors resist automation? Some view it as too expensive. While it is true that this is a front-end investment, consider the benefits of automation in cutting, nailing, and stacking pallets daily. You will realize material savings because the machinery will significantly reduce material waste and production errors. After tracking how much money is lost due to errors and waste, you can determine when you break even after investing in automation.

Involve Employees With Workforce Training and Cross-Training

Does everyone on the assembly line have the skills to take over for another employee? If not, you are at the mercy of an individual’s presence and work ethic. It is in the company’s best interest to empower workers with knowledge and flexibility to handle multiple operations. Make cross-training a regular feature of efficiency improvements in your workflow processes. When additional workers understand various workflow stages, the business benefits from their observations and possible improvement ideas.

Schedule Downtime With Preventive Maintenance Programs

If you have had to shut down your production line due to unexpected downtime and need to repair one or more machines, rethink how to deal with automation. Improve efficiency and overall productivity by reducing the risk of sudden work stoppages—schedule maintenance of your machines on days without planned operations or when the business experiences seasonal downtimes.

Measuring Success and Continuous Improvement Opportunities of Your Pallet Manufacturing Workflows

Learning how to optimize pallet manufacturing workflows for efficiency is not enough. Once you start implementing steps related to your business, it is critical to gauge how well they are working. Determining whether things work better and workflows significantly improve may take a few months. Even if you do not see the workflow improvements you had hoped for, remember that some changes require multiple steps before you find the sweet spot that works for your company.

• Identify and track key performance indicators. Examples include on-time product delivery rates, first pass yields, and the scrap rate. If you use the same production line for multiple products, remember to add changeover time as one of your indicators.
• Measure resource optimization. Streamlining warehouse operations should result in increased product manufacturing. However, monitor how the business uses the necessary resources and materials. You should see reduced labor and material costs. Industry insiders suggest a “reduce, reuse, and recycle” mindset.
• Use software for real-time analytics. When you know what is happening on your production line at any moment, you may find additional ways to adapt operations and improve output. Real-time analytics also enable you to direct team members to optimize space, palletizing, and overall operational efficiency.

Getting an Independent Third Party to Look at Your Workflow Patterns

You know your business inside and out. But are you sufficiently unbiased to attempt automated palletizing, reduce manual labor, and change the workflow process from the ground up? Many business owners realize that they can work with what they have but lack the ability to envision the integration of automation or at least software.

Working with industry insiders is critical not only for developing pallet business growth strategies via sales but also for streamlining operations through workflow adjustments. Even if you are unsure whether you are ready to make far-reaching changes at your facility, it makes sense to know your options.

The team at Pallet Company Marketing devotes time and energy to working with business owners like you to grow their operations. Specifically, we have a firm finger on the pulse of the latest digital resources available. Increasingly, staying competitive in the pallet business relies on integrating technology, software, and robots. Reach out today to learn more!