5 Things That Should Guide You in Manufacturing Process Optimization

The manufacturing industry is going through a very interesting phase. While the cost of operation is consistently going up, there is a rapid development in technology that is now allowing early adopters to enjoy success despite the tough economic times. Whatever your manufacturing area you will agree that optimizing operations has become the new route in successful manufacturing.

Gone are the days when having a very sophisticated manufacturing facility made your company the envy of the city. Today, it is more about how to adjust processes to minimize costs without compromising on productivity or efficiency.  The selection of the process to be optimized should be done after thorough studies and it is imperative to leverage the input of an established manufacturing process optimization expert.

manufacturing process optimization

Process Automation for Optimization  

In order to leverage the benefits of an optimized system, you have to take advantage of the automation technologies available today.  Process optimization works through a creation of new processes and developing new resources for the highest levels of efficiency.  A high level of efficiency guarantees better productivity and this is what every plant manager wants to achieve. Processes that are not working need to be abandoned and instead, the optimization process should adopt a lean strategy where only what works is retained.

To achieve high levels of optimization you need to continuously evaluate your existing processes whether they are manual or automated.  The optimization process is intense and requires constant testing of systems, fine tuning, adding enhancements for maximum ROI. A fully automated process is easy to optimize and increases the quality of the products. There is also an accompanying reduction in costs as the number of production cycles come down.

In a survey by GatePoint Research on the areas executives prioritize today, 90% of the respondent’s surveyed said dealing with manufacturing complexities rates at the top. These executives believe that if they are able to optimize the manufacturing process they will boost revenues and improve operations.

To get this done the survey also gave an open-ended question on what factors these executives are using in manufacturing process optimization. While every industry has its own unique challenges and variables in the manufacturing process, there emerged a clear thinking towards how most of the more successful operations are dealing with complexities in their manufacturing processes.

Among the factors that are being used to successfully guide the optimization of manufacturing include:

  1. Maximizing flexibility: This ensures more work is being achieved without necessarily resorting to more cost at any manufacturing phase.
  2. Updating process: Using the latest industrial control systems (ICS) and other technologies is a sure way of getting the most out of your manufacturing facility.
  3. Extending revenue streams by the addition of new installations to maximize production. Leveraging information systems is also an innovative way of boosting production without capital injection.
  4. Continuous tuning up of operations to eliminate wastage.
  5. Getting harmony among diverse systems for seamless operations. This eliminates duplication of tasks for more productivity and reduction of costs.


There can be no denying that optimizing your manufacturing process is the best option for your company today.  With the rapid evolution of manufacturing technologies there are so many systems available in the market and working with an automation systems expert will help you leverage these capabilities. You have to come to grip with the complexities in the manufacturing process in order to make the final call for optimization with automation being the first step.

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