The Indian manufacturing industry is a massive one. A detailed analysis shows that the Gross Value Added of the manufacturing industry at the current market price is around 403.23 billion US Dollars till Financial Year 2019. During the last 7 years, the manufacturing sector recorded a combined annual growth rate of 4.29%.
Reasons for the boost in the manufacturing industry of India :
Powered by the Make In India initiative, the country is gradually traversing the path of becoming a centre for hi-tech manufacturing as the global industry moguls like GE, Siemens, HTC, Boeing and Toshiba have either constructed manufacturing plants or are in the process of establishing them; egged by the growing number of consumers and the ever-increasing purchasing power of the nation. From the current 16%, the Government of India is aiming to increase the share of the indigenous manufacturing industry in terms of 25% of the Gross Domestic Product by 2022; that would result in the creation of 100 million new jobs in the same sector by that time.
Importance of manufacturing processes :
Seamless and lean maintenance practices in the manufacturing industry are responsible to minimise overhead costs as well as downtime; thus increasing the efficiency of the industries and improving the production. Though most of the manufacturers hold the age of the manufacturing equipment, lack of skilled and competent individuals versed in the knowledge of the trade, absence of spare parts and the extreme pace in manufacturing responsible for not being able to realise the potential that the manufacturing sector contains it is evident that establishing leaner manufacturing practices will set the course for the manufacturing and production industry in the right direction.
Steps to achieve best-in-class manufacturing processes :
The following are the steps that one may adopt in order to develop the best manufacturing practices for his company.
- Accumulation of data and calculation of downtime costs – Relevant data should be collected on machine downtime, mean time between machine failures, expenditure on machine parts and spare components, usage of technology, the response time of technicians and the percentage of on-time deliveries; which would prove crucial in establishing streamlined manufacturing operations.
- Determination of the monetary worth of maintenance – It is extremely crucial to determine how much money will maintenance improvements save and thus work accordingly.
- Analysis of operational variables – Addressing the operational variables in manufacturing results in cost savings on key maintenance operations.
- Proper investment in a technology solution – Investing in a technology solution like Computerised Maintenance Monitoring System results in the ease of handling the operational variables of manufacturing and maintenance.
- Scheduling of preventive maintenance – Scheduling preventive maintenance functions and generation of checklists to manage maintenance operations, for example, monitoring the availability of spare parts in manufacturing and production.
- Deployment of a scheduler planning function – It is crucial to have a scheduler function in order to reduce downtime and maximise the value of preventive maintenance in order to transform the existing manufacturing environment into a more proactive maintenance mould.
- Introduction of predictive tools – Introduction of predictive tools in the manufacturing industry is of utmost importance as they help in increasing the lifespan of the machines and offer easy availability of these machines at all time; without their basic functions getting hampered.
- Total productive maintenance – Gradual inclination towards total productive maintenance or TPM helps in leveraging the familiarity of the operators with manufacturing assets and thus there should be an abundance of simple and basic solutions that enlist the operators on maintenance.
- Implementation of Reliability Centred Maintenance strategy – Implementing a robust RCM strategy helps in assessing the machine capabilities and status and prevents withdrawal of equipment for preventive maintenance until failure of the concerned equipment is imminent.
- Introducing third-party technicians as and when needed – Achieving world-class maintenance in manufacturing is essentially involves a huge shift in cultural dynamics. With the shortage of skilled labourers and competent technicians, it is extremely important to bring in third-party technicians and establish the metrics as well as define the procedural actions needed to level up the production.
In short, these are the steps needed to achieve world-class maintenance practices in manufacturing and production.