The Benefits of Streamlining Manufacturing Processes and Implementing Quality Control

Richard Anderson, owner of Signarama Salt Lake City

Many sign shop owners are all too familiar with the frustration of a job going off the rails, leading to lost profits, or the disappointment of working long hours only to find that the profit at the end of the month or year just isn't there.

We are in an industry that is custom by nature and will always demand process improvement to find success. The good news is that you don’t have to accept this for your business. Instead, you can explore solutions for improvement. By focusing on culture change and process enhancement, you’ll find that manufacturing efficiency and quality control will improve as a result.

For example, there are systems that exist in today's manufacturing environments, such as Lean Manufacturing, Kaizen, and Six Sigma, that aim to provide these very solutions.
We are currently using the 5S methodology in our shop, and over the past 5 years, we have seen significant improvements in quality, employee engagement, and profit. Below are six areas that we focus on daily, weekly, and yearly to ensure these improvements remain consistent.

Reduce Production Waste: In a well-run shop, waste simply cannot exist. This is not just about material waste but a waste of time and movement. Processes must be designed and implemented to be exact and precise. Tools must be kept where they are used and be the right tool for the job.

Identify Current or Potential Bottlenecks: As we grow and improve, there will always be part of the process that slows things down. Most of these bottlenecks can be solved with technology, equipment or reorganization. You must recognize that they exist and address them promptly.

Improve Employee Performance: You cannot do this without buy-in from your employees. To a big degree, each employee must be involved in their development. Improvement in this area requires training and encouragement. Culture starts at the top, and employees must see and feel your commitment to change.

Automate Operations When Possible: You simply cannot keep up without the right equipment in today's fast paced way of doing business. Automation both speeds up the process and improves quality. The days of hand producing a product are over.

Stay Organized: We spend at least 30 minutes each day cleaning and organizing in every department. By keeping our work area clutter-free, we eliminate waste in the long run, as we no longer need to hunt for materials and tools. Things are where they are supposed to be, and everything has a purpose.

Quality Control: Develop a process where quality still takes precedence over speed. Doing a task right the first time will always be more productive and profitable than doing it fast two or three times.

"We eliminate waste in the long run, as we no longer need to hunt for materials and tools." | Credit: Signarama Salt Lake City

If we are to repeat a process frequently, and perfect that process, we must address the one-off or completely custom jobs that produce the most errors and overspend of time. This is probably one of the hardest concepts to implement. It means being focused on the products and services that are meaningful and profitable. It also means eliminating products and services that are not important to the company's success.

As you refine your processes and implement quality control, you will find a less stressful and more profitable business future. You will also notice happier and more productive employees. If you’re feeling stuck and don’t know where to start, I recommend tapping into the many resources that are available online, such as Kaizen and 5S.