According to research, up to 80% of problems in production arise before the actual production process begins and can occur at the stage of coordination, as well as in the stages of supply and engineering. This statistic may come as a surprise to many, as the focus is often on addressing issues that arise during production rather than preventing them from occurring in the first place. However, it is crucial for companies to understand the root causes of these problems and take proactive measures to avoid them.
One of the main reasons for these pre-production problems is poor communication and coordination between different departments and teams involved in the production process. This can lead to misunderstandings, delays, and errors, which can have a significant impact on the overall production timeline and quality. For example, if the engineering team does not have a clear understanding of the production requirements, they may design a product that is not feasible for production, resulting in costly changes and delays.
Another common issue is the lack of proper planning and preparation before the production process begins. This can include inadequate sourcing of materials, insufficient training of employees, and inadequate testing of equipment. All of these factors can contribute to delays, quality issues, and increased costs.
Furthermore, problems can also arise during the supply stage, where companies rely on external suppliers for materials and components. If there is a lack of communication and coordination with these suppliers, it can lead to delays, quality issues, and even supply chain disruptions. This can have a domino effect on the entire production process and cause significant setbacks for the company.
To address these pre-production problems, companies need to adopt a more proactive approach. This includes improving communication and coordination between different departments and teams, as well as investing in proper planning and preparation. This can involve conducting thorough feasibility studies, ensuring clear and detailed production requirements, and providing adequate training for employees.
Moreover, companies should also focus on building strong relationships with their suppliers. This can involve regular communication, setting clear expectations, and establishing contingency plans in case of any disruptions. By working closely with suppliers, companies can ensure a smooth supply chain and minimize the risk of delays and quality issues.
It is also essential for companies to invest in technology and tools that can help streamline the production process and improve efficiency. This can include software for project management, supply chain management, and quality control. By leveraging technology, companies can identify potential issues early on and take necessary measures to prevent them from occurring.
In conclusion, it is evident that up to 80% of problems in production can be prevented by addressing issues at the pre-production stage. Companies need to recognize the importance of effective communication and coordination, proper planning and preparation, and strong relationships with suppliers. By taking a proactive approach, companies can minimize the risk of delays, quality issues, and increased costs, ultimately leading to a more efficient and successful production process.
