In an environment full of variables and complexity, business automation helps streamline processes, eliminates manual work, and reduces human error. Be it in automobile, chemical, textile, food and beverage, electronics, or other industries, the manufacturing sector, with its intricate workflows and precision requirements, benefits immensely from adopting business automation solutions to drive these improvements.
9 most common manufacturing challenges
Many manufacturing businesses in different industries and markets share the same struggles. Here are the ones we encounter most frequently:
- Poor inventory control: Ever had your production line grind to a halt because you ran out of stock? It's a nightmare that many manufacturers face due to poor inventory control.
- Assembly line optimization grey zones: Optimization is impossible if you don't know what to optimize. Many manufacturers struggle to identify bottlenecks and inefficiencies in their assembly lines.
- Lack of single source of truth: Is your data spread across multiple systems? This fragmentation leads to inaccuracies and delays in decision-making.
- Reactionary measures: Short-term fixes may solve immediate problems but are often not scalable and require frequent maintenance, leading to more headaches down the line.
- Bill of materials: Ensuring that all parts and people are available at the assembly line on time is a persistent challenge.
- Relying on third parties: External programmers may not fully understand your processes, leading to solutions that don’t quite fit your needs.
- Quality control: Maintaining high quality in manufacturing is critical for meeting customer expectations and regulatory standards, such as the Corporate Sustainability Reporting Directive (CSRD). Identifying defects early in the production process and adhering to quality standards can be challenging but is essential for brand reputation and compliance.
- Equipment maintenance and downtime: Regular equipment failure and downtime can lead to significant production delays and increased costs. Implementing predictive maintenance strategies, where data analytics and IoT (Internet of Things) technologies predict when maintenance should be performed before equipment fails, can significantly reduce unplanned downtime.
- Labor shortages and skill gaps: The manufacturing sector often faces challenges in finding and retaining skilled workers. This can be due to a general shortage of qualified candidates or rapid technological changes that outpace the current workforce's skills.
How these challenges can be solved
Let’s look at the top benefits of automating business processes in a manufacturing business:
- Optimize order to production process. Streamline the transition from order receipt to production, ensuring an efficient workflow.
- Enhance processes with data from your ERP system. Integrate data seamlessly to enhance decision-making and operational efficiency.
- Differentiate your process. Easily adapt and modify your processes when entering new markets or introducing new products.
- Distribute data easily into your supply chain. Ensure that all stakeholders have access to the information they need, when they need it.
- Complete customer journey in one workflow. Support the entire customer journey in a single, cohesive workflow, enhancing the customer experience.
- Save costs. Automate repetitive manual tasks and replace outdated tools to save time and money. For instance, consider this: automating an order management system can save up to 52 days a year previously spent fixing human errors. That’s significant time that can be redirected to more productive activities.
Real-world examples of automation in manufacturing
There are multiple options for solving manufacturing challenges with business automation – from integrating data in one system to speeding up custom order management. Here are two real-life cases to spark ideas for your business.
Example 1: Streamlining generating special agreements on orders or contracts
Problem: Managing special import agreements via Excel was chaotic. The data wasn’t updated correctly, and multiple edits were hard to track. Payment agreements added to the complexity.
Solution: A customized application was developed to record all necessary information about unusual deliveries, including payment agreements and account manager details. This led to clear insights into supplier status and adherence to agreements.
Example 2: Order management system for a company producing 3D sculptures
Problem: Relying on multiple Excel sheets for managing orders became unsustainable as the business grew. The company had a production center in one city and customer service and 3D scanning offices across the country. The disjointed system led to frequent errors and inefficiencies.
Solution: The new order management system integrated with their booking system, eliminating data errors and ensuring a smooth customer journey. The application also allowed 3D print services to access and update production statuses in real-time, enhancing supply chain integration. This saved them 52 days a year previously spent on fixing errors.
Triggre customer story: Wikkelhouse
Wikkelhouse, a Netherlands-based manufacturer of sustainable modular homes, faced significant administrative challenges as they grew. The increased administrative tasks were stifling creativity and wasting productive time.
Using Triggre, they developed a machine planning application tailored to their production line, scalable to support future growth. This application allowed keeping track of all the CNC machines’ activity (the cornerstone of their production) and provided a clear overview of the parts in progress as well as what needed to be done next.
This transformation is highlighted in our case study.
In conclusion
Business automation solutions are revolutionizing manufacturing by addressing critical pain points and enabling significant improvements in efficiency and accuracy. If you're ready to transform your manufacturing processes, book a demo with us today and see how Triggre can help you achieve your goals.
