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How to Increase production?

Before to know how to increase production, it is important to know what production is and why it is necessary to increase production in any manufacturing industries.

English meaning of Production is? 

The action of making or manufacturing from components or raw materials, or the process of being so manufactured.



Production is a process of making finished goods by processing single raw material or combination of more than one single raw material, it may include single process or combination of process. Some finish products for one company can be finish product for next company. Production is also defined as manufacture finish goods in high volume. Apart from raw material there are other inputs in production such as manpower, electricity, machinery, Chemicals, system, money, etc.

There are two ways to produce products:

  1. Batch production 
  2. Continuous production

In batch production finish product is manufactured in batches, for say one batch is of 100 Pcs and another of 200 Pcs. This type of production is done usually on machines which are high speed and able able to finish product with different measurement scale.

Whereas in continuous production material is continuously produce till a particular period of time, specially in car manufacturing line, in a single line same type of material is produce till the required is not over. 

Why should be increase the production?

There are multiple reasons for which company should increase production:-
  1. Increase  revenue of company: It is one of the reasons why company are running. As production increase sales of company will also increase and hence revenue of company increase.
  2. Increase the profitability of company: As with same input, output will increase and all resources remain same(for example manpower, electricity, no. of machines), i.e. with same amount of investment more output and sales,  hence profitability of company increase
  3. Increase the moral of employees of company: As profitability of company increase, the shares of employees will also increase which results in positive attitude and increase moral of all company.
  4. Decrease waste of company: As more focus is toward increasing the production of company as a result improvement in process and also focus on continuous improvement results in decrease in rejection or waste.
  5. Optimum utilisation of the resources of company: by using same input resources to increase the production of results the maximum or optimize utilisation of the available resources of company.
  6. Increase customer rating of company: As production increase the delivery time of the product to the customer will decrease and making company's rating toward positive sides.
As now we are able to understand what is production and also known why it is Important to increase the production, now it is important to know how to increase the production in company.

Ways to increase the production:

There are different ways to increase the production in manufacturing industries.
One way which to increase input or raw material and increase machines or man power, output / finished product will automatically increase, this is the simplest way to increase the production but in this case efficiency may not increase. In this article we will focus to increase production by increasing efficiency of company.
 
Eight ways to increase production of company:
  1. Improve and update the process of the manufacturing.
  2. Focus on TPM (Total Productive Maintenance) and follow rigorously.
  3. Strictly adhere planned Maintenance.
  4. Focus on scrap and rejection.
  5. Increase skills of employees.
  6. Use of morden technologies
  7. Daily monitoring of production and waste.
  8. Focus on continuous improvement.

Now we discussed one by one all the above points.

1. Improve and update the process of the manufacturing:

To improve productivity it is important to trace the process of manufacturing completely, where we can find some bottle neck machines or process, unwanted process, unutilised resources are consumed like manpower, electricity, etc. 
By Gamba with different employees from different departments help us to find abnormal activities soon and after that improve the process. Once we improved the results we should measure, i.e. after improvement how much production increased.
It is not one time process it should be done on fixed interval, like 1 month, 6 months or 1 year or so.
Any part of the process that seems to improve, should improve even it looks very small. 

2. Focus on TPM (Total Productive Maintenance) and follow rigorously:

TPM is important for any system. If TPM is strictly follow in company then number of breakdown will reduce. As in our previous article related to TPM, you can get complete detail about TPM and how different pillars of TPM give strength to the company.
The objective of of tpm to increase the overall effectiveness of the equipment that is OEE by the actively involvement of all the employees. TPM is not only focus on breakdown but also make working environment safe and focus on reduction in rejection.
TPM breakdown will reduce which in a result increase the running time of machine, as running time of machine increase production output will increase. 
In safe working area employee can work more comfortably which increase moral and which ultimately help company to increase the production.
Total amount of rejection that will reduce will turn into increase in production. Rejection and production is inversely proportional to each other.

3. Strictly adhere planned Maintenance:

This topic is covered in one of the eight pillar of TPM. But we took this point seperately as it very important to timely deal and resolve the issues of machines before they stop due to breakdown. Planned maintenance is not just help to reduce the breakdown but also increase the life of the machine and increase the quantity of product.
Breakdown time is inversely proportional to the machine available time and machine available time of machine is directly proportional to production from machine. i.e. if breakdown will reduce then production from machine will increase. Planned maintenance also improve the quality of product. 
It seems that 4-6 hours are used for planned maintenance, but this planned maintenance is done with proper planning and will not effect production much but it may save may unpredictable loss time. If any machine which breakdown in night shift and some tooling part is not available in night shift or it has to buy from outside which is not possible in night shift, then machine will stop for complete night shift and day shift till machine get corrected. This unpredictable breakdown is reduced by planned maintenance.

4. Focus on scrap and rejection:

This topic is very important as reduction in scrap and rejection not only increase productivity but also save the company resources which in turn increase the profitability of the company. Time used to produce defective parts and segregation of defective products. If all product produce OK then production will increase and operator time for segregation will also save that he/she can used to to run machine, which in turn increase overall production.

5. Increase skills of employees:

Training of employees will helps to increase production. As train employees can do troubleshooting at faster rate, that will increase the available production time. Expert employees also decrease the job setting time on machine and made machine available faster as compare to less train employees do setting. By training, moral of employees increase and high motivated employees tries their best to produce better production from machine. All these results in increase in production. 

6. Use of morden technologies:

To increase production we should also think beyond convectional tradition or technologies. By Industry 4.0 we can take advantage of digitalisation to increase production of machine. With the help of Digitalisation we can track the machine utilisation or the machine spare that is time when machine is not used for the production, by proper data we can increase production time on  machine. When is the production time on machining crease the productivity for the organisation will increase. Same can be used to know the time when is should important or critical spares of machines to change so that breakdown time can be reduced which other result increase in the production.
With help of technology communication between plants or sites will increase, this will help to do horizontal developed of good work (that increase production) in one plant, can be implemented into another plant.

7. Daily monitoring of production and waste:

To improve any process it is important to have daily monitoring of the process. Same is applicable to reduce rejection of the system or the process. By daily monitoring we can able to understand that in which process rejection percentage is more and where we have to concentrate or take steps to reduce the rejection. We have to do proper root cause analysis, we can reduce rejection, by taking proper step to reduce the rejection it should be continuously monitor so that if there is any further improvement that can be implement soon to reduce further rejection. 
As rejection reduce the production will increase. Rejection is inversely proportional to production, i.e. if rejection decrease production will increase. This is because the time used for production of rejected materials is used for production of OK material which is ultimately gain the overall production. As rejected materials are not counted in production, so it is one of the factor that effect production of OK material.

8. Focus on continuous improvement:

There is no perfect point for any process there is always scope of improvement, so make process or system better and best we have to do continuous improvement, which will ultimately results in better production, reduction in rejection, reduction in machine breakdown time and increase the machine availability time, all these factors with continuous improvement, increase the production for company and gain profitability.
Once we achieve something good we should sustain that growth for some time then focus on further improvement, this will also help us to learn something new and increase moral of employees. 


As we now able to know how to increase the production in a manufacturing company. Continuous increase in production is necessary to meet out growing demand of the market and to remain sustain in this high competitive world.
Your comments are highly appreciated and these help us to improve further. 

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