Jerry Dolinsky is the CEO of Dozuki, a leading connected worker solution for enterprise-level manufacturing companies.
I find immense value in addressing the challenges faced by plant managers across the industry. Their jobs are among the hardest in manufacturing. They have to ensure consistency across a spectrum of operators on the frontline team while connecting those operations to corporate-wide transformation efforts.
Below, I’ll explore those plant manager challenges and provide actionable recommendations to overcome them.
Challenge 1: Disconnected Systems And Inefficient Processes
In the digital age, the persistence of disconnected paper systems impedes efficiency gains. Yet, outdated and inefficient processes continue to be the norm, affecting the industry’s agility. McKinsey researchers report a mere 3% success rate for digital transformations that neglect frontline engagement.
What plant managers must remember is that the process transcends mere actions. It also should embody a vision for collaborative problem-solving.
If your team struggles with this challenge, here are my recommendations:
• Use the tech-savvy younger workforce to bridge the knowledge gap. Recognize that every facility comprises both experts and non-experts, providing an opportunity for collaboration.
• Implement a framework for precise instructions. Maintain concise, focused instructions. Provide workers with a standardized framework for constructing processes.
Challenge 2: Knowledge Deficit And Content Debt
A significant deficit arises when plant managers fail to provide broad access to essential knowledge. This content debt incurs real costs at both the frontline and managerial levels. Just know this: Failure to extract and make use of internal knowledge hampers scalability.
When I work with manufacturing leaders, here’s what I suggest they do:
• Simplify operators’ access to procedures on the floor. Upload the procedures onto multiple tablets. Complexity can be nearly as detrimental as inaccessibility.
• Install digital codes on machines for streamlined access. This ensures seamless access, eliminates confusion and prevents the use of outdated procedures.
Challenge 3: Attrition Due To Poor Training
Plant managers grapple with the loss of promising new workers due to inadequate training. The aging workforce, coupled with the difficulty in attracting and retaining talent, poses significant challenges. In 2023, ManpowerGroup researchers found that 77% of firms globally were having difficulty attracting talent and filling their open positions.
We also know that competency based solely on observation is insufficient and prone to errors. Training recommendations that I’ve found to be most helpful for manufacturers include suggestions to:
• Shift from traditional shadowing to robust education. Ensure your operators comprehend the big picture through a “read and agree” process, supplemented by quiz modules to assess their understanding of the training material.
• Implement retraining to avoid safety risks. Retraining helps ensure continuous compliance and fulfills due diligence requirements, which reduces the fear of audits.
Challenge 4: Outdated Communication Methods
Communication inefficiencies plague the industry, with updates distributed in cumbersome binders or via email. It’s hard for many plant managers to accept, but dusty binders and dated communication methods hinder progress. If you want to move your work instructions and SOPs into the next generation, here’s what you should do:
• Facilitate seamless feedback channels for continuous improvement. Without team-wide empowerment to contribute, there’s a risk people will execute tasks correctly but without updating the work instructions.
• Embrace digital platforms for technical problem-solving. Frontline workers must be able to post questions and crowdsource support without needing an email address or sharing logins, ensuring universal employee participation.
Ultimately, addressing these operational challenges demands a collective effort. Whether it’s disconnected systems, content debt, poor training or outdated communication methods, most plant managers have their work cut out for them. By implementing these recommendations, plant managers can not only overcome existing hurdles but also pave the way for a more agile, efficient and competitive manufacturing industry.
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