According to research, up to 80% of problems in production arise before the actual production process begins and can occur at the stage of coordination, as well as in the stages of supply and engineering. This statistic may come as a surprise to many, as the focus is often on addressing issues that arise during production rather than preventing them from occurring in the first place. However, it is crucial for companies to understand the impact of pre-production problems and take necessary measures to avoid them.
Pre-production problems can range from delays in material delivery to design flaws and miscommunication between departments. These issues not only cause delays and disruptions in the production process but also result in increased costs and decreased efficiency. In some cases, they can even lead to product recalls and damage to a company’s reputation.
One of the main reasons for pre-production problems is the lack of coordination and communication between different departments involved in the production process. This can be due to siloed working environments, where each department works independently without considering the impact of their decisions on other departments. For example, the engineering team may design a product without consulting the procurement team, resulting in a design that is not feasible or cost-effective to produce. Such issues can be avoided by promoting cross-functional collaboration and communication within the organization.
Another common cause of pre-production problems is the lack of proper planning and forecasting. Many companies underestimate the importance of thorough planning and rush into production without considering potential risks and challenges. This can lead to delays, quality issues, and increased costs. To avoid such problems, companies should invest time and resources in proper planning and forecasting, taking into account all aspects of the production process.
In addition to coordination and planning, the quality of materials and equipment used in production can also contribute to pre-production problems. If the materials or equipment are of poor quality, it can lead to defects in the final product, resulting in rework and delays. To ensure the quality of materials and equipment, companies should have strict quality control measures in place and work with reliable suppliers.
Moreover, pre-production problems can also arise due to inadequate training and skills of employees. In today’s fast-paced and constantly evolving manufacturing industry, it is crucial for employees to have the necessary skills and knowledge to handle complex production processes. Companies should invest in training and development programs to equip their employees with the skills needed to identify and address potential problems before they occur.
To address pre-production problems effectively, companies should also have a robust risk management system in place. This involves identifying potential risks and developing contingency plans to mitigate them. By proactively addressing potential risks, companies can minimize the impact of pre-production problems on their production process.
In conclusion, pre-production problems can have a significant impact on a company’s production process, resulting in delays, increased costs, and damage to reputation. However, by promoting coordination and communication, proper planning and forecasting, ensuring the quality of materials and equipment, investing in employee training, and implementing a robust risk management system, companies can prevent these problems from occurring. It is essential for companies to understand the importance of addressing pre-production problems and take necessary measures to avoid them, ultimately leading to a more efficient and successful production process.
