Inefficiencies can affect every part of food manufacturing operations, from lost time to damaged goods and other unnecessary costs.
‘Waste’ can be defined as any activity that consumes resource but doesn’t add value. By focusing in on reducing operational waste, you can expect to see improvements throughout your process. From increased space utilisation, time saved, reduced damage and improved safety, it is vital to identify inefficient processes and find the solutions to improve them.
Where does ‘waste’ lie?
- Slow manual processes – slow manual processes throughout a production flow can cause inefficiencies, including errors, slower throughput, and safety concerns.
- Food spoiling - Improper storage, inadequate equipment and damage can lead to excessive food spoilage which could prove costly and wasteful.
- Mismanaged storage – inefficiently planned storage can lead to fewer goods being stored than possible. This could lead to an increase in storage costs through having to invest in additional space. Inflexible storage can also cause issues during seasonal peaks where demand may increase.
- Poor visibility of forklift fleet – a lack of information on which trucks are being used, how they are being used and where damage is occurring makes it difficult to identify inefficient practices.
- Unsafe practices – a lack of an effective safety culture can lead to increase in incidents and extended downtime.
- Downtime & delays – a lack of regular maintenance and misuse of equipment can lead to breakdowns, damage and injuries, leading to a decrease in productivity and extended delays
- Bottlenecks – Slow inefficient processes in areas such as loading, unloading, production and storage can lead to bottlenecks which slow down the entire operation, creating waste and increasing costs.
What can you do to improve efficiency?
- Assess your existing workflow – By looking at every aspect of your operations and analysing where inefficiencies occur. You can highlight bottlenecks and better identify how to make existing processes leaner.
- Just in time replenishment – minimise overproduction, excess storage and expiry related waste to cut down on food spoilage
- Standardise cleaning and changeover processes- reduce downtime between product runs while maintaining hygiene standards with standardised practices throughout your operation
- Consider introducing automation – By automating repetitive processes, errors are reduced, workflows are streamlined resulting in a faster throughput.
- Implement an effective storage solution– By implementing effective storage solutions such as racking, automated shuttles and VNA trucks, you can maximise on existing space rather having to invest in a larger premises.
- Utilising fleet management technology – By utilising effective fleet management solutions, you can benefit from greater visibility of your trucks. The data collected allows you to oversee fleet utilisation and energy usage as well as manage operators.
- Develop an effective safety culture – through implementing effective forklift operator training and investing in safety systems, the likelihood of accidents happening are reduced. This in turn leads to less downtime and damage and increased productivity.
- Identify the right energy source for your operation – choosing the right energy solution for your truck fleet is crucial for maximising efficiency while supporting sustainability goals.
Making incremental changes to each aspect of your operation can have a massive impact on the overall efficiency of your business. Through reducing inefficient processes wherever possible, you can improve safety, reduce costs, save time and minimise spoilage.
Find out more about how we can support your operation to improve efficiency through our Zero Muda (zero waste) approach here: https://toyota-forklifts.co.uk/food-manufacturing/