Here's how you can overcome key challenges in manufacturing as an executive.

With evolving technologies, now many possibilities have been opened for organizations to focus on. It can be any segment of the organization; we can implement customized solutions for maximizing the VALUE generated from the entire Value Stream. Also, we must ensure the synergy of these technologies to maintain the appropriate flow in Operations. If we implement too many technologies, a gap can arise, which could become a major concern for adaptability for the organization, also if we are too dependent on single technology, we are never sure, when it can cause major failure for our Business operations. Yes, we must go for innovative ideas, but we must understand the benefits of it to the Organization and how it can boost our operations.

Yes, implementing cutting edge technology not only gives relief about labor shortages and workforce issues. But the most important thing is to mold your floor shop designs and value stream mapping according to newly implemented technology. It's not easier to design technologies where there are a variety of products. Every product has different behavior from one another. So a feasibility study would help either it's beneficial for you to implement IOT or not.

Lean Manufacturing only implemented where there is actually strong liaison between your system and shop floor. If there are any flaws in the system, you're unable to eliminate the non value added activities. These non-value added activities drain your energy, time, resources and as well as you'll lose confidence to grow. The system makes culture, improves efficiency and thus the learning of people highly relying on this. If culture is mature, then you can eliminate all non-value activity and grow in a positive manner.

For Lean Manufacturing implementation, mostly we discuss about implementation of system for identification of the various MUDA within the system but to do the same, we need to upskill our People. If the culture itself inclined towards using the "old methods", then even with multiple systems setups for identification of non-value-added activities, we fail. We should take an approach to constantly be on GEMBA and educate the shopfloor in questioning the practices and finding out solutions to optimize the work. This builds the culture and gives us the momentum needed to discuss about various Lean Manufacturing Tools.

Trainings should be initiated about the understanding and enhancement of workers. Periodic training in a month will reduce the chances of discrepancies or non conformances.

Training needs identification is a never-ending process. It should be viewed from both, organization, and employee perspectives, to find the right Training for skill upgrade. Both should focus on developing the skills, which are needed for optimizing and driving the existing systems and to develop new lean practices. Basis the same, appropriate Training Calendar can be made to cater the needs of skill upgradation. Also, organization should develop internal talent for providing the necessary trainings inhouse with internal trainers to make everyone comfortable with discussion on real-work life experiences.

Supply Chain must ensure the implementation of that software which reflects the right or standard quantity of product to be produced and whether it's timeline to dispatch. This only happens when shortages of raw materials should be analyzed before posting SO (Sales Order) in a system. If your Sales staff is not competent to draw an accurate forecasting with least error occurrence, then neither shortages would be eliminated, nor timeline achieved and you'll be unable to implement a software. Although designing software couldn't be initiated.

Agreed. Resolving a customer problem by developing a great product will not only strengthen the customer relationship it also opens up the opportunity to offer similar solutions to other customers which consequently increases the load for your operations

Performing Risk Assessment is a must and should be given the utmost priority in any organization for safe working environment. We must train our employee in identifying the hazards and reporting the same, which helps us in making everyone understand the importance of mitigating the risks. This builds Safety culture, which helps us in enforcing rigorous usage of Risk Assessment tools. Only with Risk Assessment, it is possible to identify the gaps, either major or minor, in the procedures, protective equipment and work areas. With the gaps identified a route map can be built to close them with effective safety solutions.