An insight into first-rate project management to deliver your production line
As you introduce new products and processes into your plant, there will be times when you need to expand your operations to include additional production lines. Doing so will require careful consideration of what you want the new line to achieve, how it will work logistically and how you will efficiently install it into your factory.
When adding a new production line to your workplace, you will naturally want to make sure it is done effectively, leaving no room for error, so that it brings the intended results. To successfully achieve this, you need to have first-rate project management.
A well-managed project should have the necessary planning, using the right machines for your business needs, which are installed correctly and deliver results. In this blog, we have detailed what steps you should take in your project management to make this a reality.
Planning
The first step of any new processing project is planning what it will look like. As part of this, you will outline what the intended purpose of your new line will be. This includes understanding what substances will be running through the line and what the result needs to be. For example, will you need to inspect the products for contamination? Will the product need to be sorted into set weights and packaged? This will help you to detail what elements you need to include in your line, such as multihead weighers, checkweighers, packaging machines or x-ray systems.
You will also need to identify how the new line will work with your existing plant layout. This includes determining whether staff working on the line will have the appropriate space away from other operations, if the new line will need to fit in with any existing lines or equipment and what the workflow of products will be.
Other things to consider in your plan are what requirements you need the production line to meet, in line with the substances you will be running through it. This could include using machines that ensure gentle handling, are hygienic or are waterproof so that you can make sure productivity is high and your goods are handled in the right way.
Be sure to document your plan so you can refer to it as the project progresses. The plan can also be shared with key stakeholders in your company to get their buy-in and showcase how you will ensure success with the new line.
Find the right partners
Once you know exactly what you need in your production line, you will need to find partners who can provide the different elements you need and work with you to make the line a reality. Spend time researching partners so you can find the right fit for your project.
The first step when looking for a partner is making sure they offer the machines and equipment you want to implement in the line. You may choose to get all the components you need from one partner or work with a collective of partners. The advantage of working with one provider is easier management of fewer stakeholders. However, there may be times where your chosen partner does not offer everything you need, or you find more suitable solutions from an alternative partner. If you are working with multiple partners, make sure that the machinery they are individually supplying will work in conjunction with each other, so your line performs effectively.
When comparing different partners, take time looking at the specifications of the systems they offer. You should make sure any machine you choose is compatible with your products and meets the requirements of your project. Beyond this, you may also wish to check things like accuracy, speed, IP rating and any additional features the partner is able to offer. As well as this, you should find out if the machines meet the right standards (such as HACCP) as this will allow you to ensure compliance in your production and identify whether the partner is credible.
You may also consider the services your partner offers. Beyond providing you with the equipment you need, you will also want a partner that can assist with the fitting of the line, offering bespoke solutions for your needs, training of employees and technical support after the line has been installed. This will give you peace of mind that you have the right help in place during the lifetime of the project, including if anything should go wrong – and can lead to a great partnership. In addition, it allows you to identify the total cost of ownership.
Installation
Once you have planned the project, identified the machines you need and found the perfect partners to supply them, you will be ready to install the line into your plant. In order to make sure the production line works properly, installing it correctly is fundamental.
You should have already considered the logistics of installing the line in your plan, including where it will be installed, the layout and what components need to be connected to one another. This plan should act as a blueprint, and the line should be installed in line with it.
As the installation of your line is so vital, you should find a suitable project engineer to oversee this. This will ensure the line is fitted to specification and in a fully functional way. Seek engineers who have the skill level needed to do the job, whether this is an internal resource or via an external company.
As previously mentioned, most partners will be able to install your machine for you when you purchase from them – it is hugely beneficial as they will have know-how and expertise to install and set up their equipment exactly as you need it to perform.
Train your staff
Next, you need to make sure any relevant employees that will be working on the new line have the appropriate training. Training is crucial to making sure those working on the line can remain safe. It will also increase productivity on the line, as employees should know what their role is and how to operate the equipment efficiently.
You will want to organise training before the new line beginning production. By doing so, you can ensure that your workforce is prepared for the new operations and are performing to the required levels. This means understanding what roles you need to have on the line, appointing staff to fulfil them and arranging training sessions.
Your training programme should include information on how to operate all the machines that form the production line, as well as any processes you want your staff to follow. The best way to seek this information is from the partners themselves, so make sure that they can provide relevant manuals or product demonstrations. Some partners may even offer their own training solutions that can be held on-site with your employees.
Utilise support and maintenance
Once your production line is installed and your staff appropriately trained, you are ready to begin production. Assuming everything has been set up correctly, the line should be able to operate effectively for years ahead.
However, with any production line, there is always the chance that line will derogate with time as the machines get regularly used, due to build-up of product, environmental impact and human error. One way to reduce risk in your line is to regularly maintain it and make sure the equipment is calibrated by the partner who set it up. By doing so, any abnormalities or issues can be identified ahead of time and fix them before they disrupt your operations. You can also make sure each machine is working at an optimal level to enhance productivity.
If there is an issue in your production line, such as a broken machine, you must utilise the right support to repair it. An issue with even just one part of the line has the ability to entirely halt production, lead to product discrepancies, increase wastage and reduce output, so it is imperative to identify and fix it as soon as possible. As such, it is worth considering having a maintenance contract in place with an external provider who can address any repair needs quickly – particularly if you don’t have internal resource for this. It is ideal if your machine partner can provide this, as they will have in-depth knowledge of the equipment and how to fix it.
By regular maintaining and utilising repair support on your production line, you can extend its lifespan and keep it working in good condition – which in turn can promote better productivity and return on investment. Another point to consider is, if the equipment is not maintained in accordance with the manufacturers guidelines, that any warranty may become invalidated.
Summary
By following the steps outlined above, you can ensure that your project runs smoothly from the planning stage to its final installation in your factory. As a result, you can benefit from the implementation of a production line that fits the intended timescales of the project, is built to fulfil requirements and works logistically in your plant.
With efficient management, utilisation of the right partners and making the most of additional support, you will have a new production line that yields results. Further, these results can continue to build long-term as your production line stands the test of time.
If you need support in bringing your project to life, Yamato can help. We provide bespoke solutions depending on the unique needs of your production and can work with you to find the best machines to align with your goals. We also offer support throughout the process, including planning, installation, staff training and maintenance of your production line, so you can benefit from our assistance in the long run.