6 ways to increase operational performance - Small Changes, Big Wins.

Six strategies that will deliver big wins in operational performance

Manufacturing facilities are complex, and often highly complex environments where inefficiencies can often creep in. For UK manufacturers, success hinges on doing more with less—less waste, less downtime, and fewer resources—while maintaining high-quality standards.

The good news? Achieving these goals doesn’t always require hefty capital investments or major overhauls. It’s often the small, strategic and tactical changes that make the biggest impact.

From optimising workflows to embracing data-driven decisions, UK manufacturers are proving that incremental improvements can drive substantial results. Let’s uncover how simple, yet powerful tweaks can revolutionise efficiency, reduce waste, and boost productivity. Explore the six key strategies that keep manufacturers competitive in a demanding market.

1. Workflow optimisation: Small Tweaks, Big Impact

One of the easiest ways to improve efficiency is by optimising workflows. This doesn’t require reinventing the wheel—just rethinking how tasks are organised and executed.

  • Rearrange workstations: A poorly designed workstation can lead to wasted time and unnecessary movement. By rearranging equipment and ensuring tools and materials are within easy reach, manufacturers can minimise delays and keep production flowing smoothly
  • Eliminate unnecessary steps: Take a close look at your production process. Are there redundant steps that can be removed? Streamlining workflows by cutting out inefficiencies can significantly reduce production times
  • Use visual aids: Clear signage, color-coded labels, and visual guides can help employees quickly understand processes, reducing errors and speeding up tasks

Taking taking steps to redesign assembly lines will reduce the distance workers have to move between stations will help to reduce production time and reduce fatigue among employees, leading to fewer errors.

2. Embrace preventative maintenance

Equipment breakdowns are one of the biggest culprits of inefficiency in manufacturing. Unplanned downtime can bring production to a halt, costing time and money. Preventative maintenance is the key to avoiding these disruptions.

  • Regular maintenance schedules: Implementing a routine maintenance plan ensures that equipment is always in top condition. This reduces the likelihood of unexpected failures and extends the lifespan of machinery
  • Train operators: Equip your team with basic maintenance skills so they can identify and address minor issues before they escalate
  • Keep spare parts on hand: Having critical spare parts readily available minimizes downtime when repairs are needed

Implementing a preventative maintenance program for machines helps address wear and tear early, leading to a reduction in unplanned downtime and increased overall output.

3. Leverage data analytics

Today, data is a manufacturer’s best friend. By harnessing the power of data analytics, companies can identify bottlenecks, monitor performance, and make informed decisions.

  • Monitor KPIs: Key performance indicators (KPIs) like Overall Equipment Effectiveness (OEE) provide valuable insights into how well your equipment is performing. Tracking these metrics helps pinpoint areas for improvement
  • Real-time monitoring: Use sensors and software to collect real-time data on machine performance. This allows you to address issues as they arise, rather than after the fact
  • Identify trends: Analyse historical data to spot patterns and predict potential problems before they occur

Data analytics help to identify recurring bottlenecks in production, and by adjusting these workflows and reallocating resources, companies can reduce production time and improve production consistency.

4. Engage and empower employees

Your workforce is one of your most valuable assets. Engaging employees and encouraging their input can lead to innovative solutions and a more efficient operation.

  • Cross-training: Train employees to perform multiple roles. This not only increases flexibility but also ensures that production can continue smoothly even if someone is absent
  • Encourage suggestions: Create a culture where employees feel comfortable sharing ideas for improvement. Often, those on the front lines have the best insights into what’s working—and what’s not
  • Provide feedback and recognition: Regularly acknowledge employees’ contributions and provide constructive feedback. A motivated workforce is a productive workforce

5. Reduce waste and Optimise Inventory

Waste is the enemy of efficiency. Whether it’s excess materials, energy, or time, reducing waste can have a significant impact on your bottom line.

  • Just-in-Time inventory: Adopting a just-in-time (JIT) approach minimises storage needs and ensures materials are available exactly when needed
  • Energy efficiency: Simple changes like upgrading to energy-efficient lighting or optimising machine settings can reduce energy consumption and lower costs
  • Recycle and reuse: Look for opportunities to recycle materials or repurpose waste. Not only does this reduce costs, but it also supports sustainability goals

6. Adopt technology and automation

While this blog focuses on small changes, it’s worth noting that even modest investments in technology can yield significant returns.

  • Automate repetitive tasks: Use software to automate tasks like inventory tracking, order processing, and quality checks. This frees up employees to focus on higher-value activities
  • Implement OEE Monitoring: Overall Equipment Effectiveness (OEE) software provides real-time insights into equipment performance, helping you identify and address inefficiencies quickly
  • Upgrade outdated equipment: While not always a small change, replacing outdated machinery with more efficient models can dramatically improve productivity

With Intouch Monitoring there are many real-world examples of the benefits of using an MES or Manufacturing Execution System, which includes OEE monitoring and linking in with production planning. Typical results can be anywhere between 10% and 25%, often in as little as a couple of months from implementation

Conclusion: Small Steps, Big Results

The efficiency revolution in UK manufacturing isn’t about making sweeping changes overnight. It’s about identifying small, actionable improvements that add up over time. By optimising workflows, embracing preventative maintenance, leveraging data, engaging employees, reducing waste, and adopting technology, manufacturers can achieve significant gains without breaking the bank.

The key is to start small, measure the impact, and build on your successes. Whether it’s rearranging a workstation, training an employee, or implementing a new software tool, every change brings you one step closer to a more efficient, productive, and profitable operation.

UK manufacturers are leading the way, proving that even in a challenging industry, small changes can lead to big wins. The question is: what’s your first step?

Here at Intouch Monitoring, we have a team of experienced manufacturing professionals who are ready to help you start your journey towards manufacturing excellence.

How it works

Getting started with Intouch is as easy as 1, 2, 3

1. Book a demo

Let us show you what we can do. Jump on a demo call and our friendly team will take you through the Intouch system and answer any questions you might have.

2. Enjoy a free trial

Don’t just take our word for it! We’ll lend you our technology for a 60-day free trial so you can see exactly how it can benefit the everyday operation of your business.

3. Receive ongoing support

It doesn’t end there. If you decide Intouch is the right production monitoring system for you, we’ll work with you to help you take control and make significant improvements in OEE.

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