Complete guide to manufacturing workflow management

The manufacturing sector has a multitude of complex processes that are data- and labor-intensive, making management a real challenge for the industry. Implementing an efficient workflow for manufacturing that includes processes to manage the machinery and people involved is the most effective solution.

When done right, workflow management in manufacturing boosts operational success by increasing efficiency and productivity. This improves quality and ensures proper resource allocation. As a manufacturing professional you can use these workflows to strengthen communication, adaptability, and customer satisfaction while decreasing errors and stress.

In this guide, we cover what workflows for manufacturing are, common types, and insight into the key benefits and challenges to help improve your workflow processes.

What is a workflow for manufacturing?

A manufacturing workflow is a process guide to help manufacturers increase efficiency. It can help cut costs and maintain production time without sacrificing quality. With increased competition and rising labor costs in manufacturing, these workflow processes are critical.

Essential components of a manufacturing workflow include:

• Planning and design: Development of product designs and production plans with specifications and resource requirements.
• Material sourcing and procurement: Acquisition of raw materials and components needed to start production.
• Production scheduling: Creation of a timeline to guide the manufacturing process.
• Manufacturing and assembly: Execution on production, including machining, assembling, and testing all component parts.
• Quality control: Inspection and testing of products to ensure standards and specifications are met.
• Packaging and distribution: Preparation of finished products for shipment, from packaging to delivery logistics.
• Inventory management: Tracking of raw materials, items still in production, and finished goods to maintain supply and resource efficiency.
• Maintenance and support: Performance of regular equipment maintenance to address issues and keep operations running smoothly.

Types of manufacturing workflows

A workflow for manufacturing can be broken down into two models: push and pull. Production in a push model is driven by forecasts and schedules based on anticipated demand. A pull model is driven by actual demand, with goods produced only when there is a confirmed order or need.

There are six main types of manufacturing workflows that can either fall into a push or pull model based on how production and inventory are managed. These six types of workflows are:

• Job shop: A variety of products with different specifications can be made, like small batch orders or customized items.
• Batch: Goods are produced in batches, or groups, using the same production steps and allowing for adjustments in between each batch.
• Assembly line: Products go through a sequence of workstations with each performing a specific task within a continuous and repetitive sequence or process.
• Continuous flow: Manufacturing is done in a constant, uninterrupted flow.
• Cellular: Workstations are put into cells dedicated to producing specific items or product families.
• Project-based: Large, unique, or complex projects are individually managed with specific, non-repetitive processes.

What is workflow automation in manufacturing?

Workflow automation in manufacturing is the use of technology to streamline and automate the stages of a production process. This ranges from planning and scheduling to execution and quality control. Workflow automation is used in manufacturing to improve efficiency, accuracy, and consistency while reducing manual work and human error.

Automation technology provides the tools and systems needed for implementing, managing, and optimizing processes effectively. From precision to consistency to speed, it ensures high-quality products and reduces the time needed for assembly inspection and material handling. The technology also cuts down on operational costs, reduces waste, and improves workplace safety.

Related read:Transform your business with AI workflow automation

Benefits of a streamlined manufacturing process workflow

Streamlined manufacturing process workflows let you respond more effectively to market changes, driving operational success. The following are key benefits for the manufacturing industry.

Increased efficiency

Production can be completed faster, reducing delays and removing bottlenecks. Data shows that the average cost of downtime per manufacturing plant in a year averages $172 million. So, improving the flow of materials and information optimizes efficiency and stops downtime.

Elevated quality

Standardized processes cut down on variability in production, leading to more consistent product quality and fewer defects. Better workflows also aid in the early detection of issues for quicker corrections and solutions.

Reduced cost

Better inventory management reduces the need for excess stock and associated holding costs. You can lower your operational spend as these workflows reduce the need for more labor, minimize waste, and decrease production costs.

Faster time-to-market

Quicker turnaround times get products to the market sooner. Improved workflow efficiency makes it easier to adapt to changes in demand and accelerate production where and when it’s needed.

Better resource management

You can optimize performance by using streamlined workflows to make sure machinery, materials, and labor are used effectively. Improved task scheduling and coordination helps with the successful allocation of resources and avoids conflicts.

Amplified communication and collaboration

Clear guidelines and detailed steps facilitate seamless communication among team members and across departments. As a result, different parts of the production process become more collaborative, enhancing overall teamwork.

Greater flexibility and scalability

Easily adjust processes to accommodate new products, changes in demand, and modifications in production methods or schedules. Efficient workflows are adaptable and scalable so you can expand or decrease production based on market conditions.

Enhanced data and insights

Data collection brings valuable insights to production performance, showing areas for advancement. Access to accurate and timely data supports better decision-making and continuous process improvement.

Improved safety

Safety protocols and equipment designed to protect workers can help maintain a safer production environment. Using streamlined processes to eliminate unnecessary steps can reduce risks of accident or injury.

Higher customer satisfaction

Improve customer satisfaction and retention with reliable product quality and on-time delivery. Continually providing faster production and delivery times improves the long-term customer experience, helping teams meet market demands more efficiently.

3 challenges in manufacturing workflow management

The benefits of streamlining a manufacturing process workflow are clear, but there are common obstacles you will need to overcome. Below are the top three in the manufacturing industry.

1. Integration and complexity

Manufacturing tech stacks often involve disparate systems such as ERPs, MES, and PLCs. These need to work together to be successful, but poor integration leads to data silos, communication breakdowns, and workflow malperformance. This specifically affects decision making during the production process.

2. Demand forecasting and planning

Shifting market conditions, customer preferences, and disruptions to the supply chain make it difficult to accurately forecast demand and plan production schedules. This can lead to either overproduction or underproduction. Globally, overproduction accounts for roughly $163 billion worth of wasted inventory each year. Underproduction can lead to mass shortages, such as what was experienced during the COVID-19 pandemic.

Change management and flexibility

When implementing new processes and technologies, careful planning and comprehensive management are key to make sure transitions are smooth. Lack of training, resistance to change, and disruptions in tech migrations all hinder workflow productivity and team morale.

Improve your team’s manufacturing process workflow with automation

Automated technology is crucial for the manufacturing industry to achieve quality production. Key challenges like integration complexity and demand forecasting must be addressed for seamless data flow and reduced errors or inefficiencies.

It’s essential you create a plan for implementing or improving your manufacturing workflow. Integrate technology to streamline the process and boost production. Be sure to develop clear standard operating procedures, so everyone involved in the production process follows the same steps to maintain consistency.

Use this guide to help you understand the types of manufacturing workflows, the benefits that best support your needs, and hurdles you must overcome to make sure your solution will work.