Standard work is the no-brainer path to a more agile and efficient manufacturing team. You can tell, because so many variations have been invented to help refine and deploy the methodology. But the truth is it doesn’t really matter if you use Lean Six Sigma, Toyota Production System, Integrated Work Systems, or some other manufacturing operating system.
What matters is whether or not you can get your people to follow it.
Over the last several years manufacturing has experienced a wide range of challenges and increasing opportunities for improvement. Here are the top three trends to focus on in 2025, along with a guide to how you can master them all if you’re successful at deploying standard work.
The workforce shortage plaguing manufacturing won’t let up any time soon. In fact, the US alone could require as many as 3.8 million new employees by 2033. Of those, nearly two million jobs will go unfilled.1
That makes employee retention a critical goal for all manufacturers. Retention continues to be a challenge for many companies, particularly among roles requiring specialized skills and experience.
High engagement leads to higher productivity, less turnover, and a better-performing company. But in 2024, only 45% of workers rated their morale as high—a decline since 2023.2
In the simplest of terms, employee engagement drives employee retention at most companies. Those that struggle with retention are also frequently challenged to help employees feel confident in their work. Inadequate training and a lack of on-the-job resources make it difficult for employees to do the right thing. That can lead to performance anxiety and errors that create turnover.
Engagement and overall worker satisfaction isn’t just about higher pay. Companies with high retention rates provide guidance for employees to complete standard work safely, accurately, and efficiently. This helps employees develop confidence by making training for competence an integral part of the job.
Businesses with the best retention rates are quick to remove unnecessary obstacles. They also request employee feedback to help drive process improvement.
Probably most importantly, they create visibility for employee skill development opportunities and career advancement. Both incentivize employees while making the company more agile.
In other words, these businesses make it easy for employees to do the right thing and harder for them to do the wrong thing.
A constrained labor market renders the need for technological advancement even more relevant and urgent. But that’s not the only driver for companies investing in Industry 4.0 technologies like cloud computing, Internet of Things (IoT), and advanced automation.3
Manufacturers that successfully incorporate technological improvements will quickly increase efficiencies, deliver on sustainability initiatives, and bring new products to market faster with fewer quality issues.
As companies deploy new software and equipment, their ability to reap the benefits often boils down to the ability of their workforce to adapt to the new tools. Companies that struggle to manage change will struggle to show return on investments. In some cases they’ll fail to launch altogether and chalk up a major loss on investment.
Manufacturers with a strong operating management system and a culture built around standard work are ahead of the curve. It’s easier to change processes and reskill employees if they’re already accustomed to following One Best Way processes to complete critical tasks.
Those deploying digital work instructions and other on-the-job tools can train employees on new equipment and software as they work, avoiding long periods of downtime. They’ll experience less confusion and turnover as employees view structured upskilling or cross-training opportunities as beneficial to their career.
Disruption is the new normal this decade. Few anticipated the continued instability wrought by the pandemic, the global supply chain disruption, and the increasingly severe weather events we’ve been experiencing. Manufacturers that have become more agile have responded quickly to disruption.
If you feel like we’re through the worst of it, you’re in the minority. Increasingly demanding regulatory requirements,4 cyberattacks,5 and a greater need for supply chain resiliency6 are just a few of the likely issues we’ll face as we move into the future.
Although it’s important to have business continuity events prepared for any potential outcome, it’s more important that your individual team members know how to react when the time comes.
Organizations that haven’t deployed standard work can’t respond quickly to the unexpected. They can’t get their employees on the same page or show them how to determine if they’re doing the right thing.
Even companies that have spent millions with consulting firms to develop intricate policies and procedures can find themselves struggling during an emergency. If protocols sit on shared drives and in binders, but never make it into employees’ hands, they’re not worth the paper they’re printed on.
When organizations make their procedures easy to access and follow, their teams can move as one in response to a situation.
Employees who are already accustomed to accessing standard work from a dynamic, centralized system will know where to turn when they encounter the unexpected. The really good systems will enable you to instantly deploy changes that are immediately incorporated into daily activities with minimal need for prolonged training programs.
Your success depends on developing new products that meet consumer expectations of variety and quality, while simultaneously delivering on shareholder demands for growth and efficiency. Increasingly, your ability to balance these objectives while dealing with unexpected curve balls is the norm.
Incorporating a platform that empowers employees to autonomously follow standard work requirements is the future of how work gets done.
Whether you’re just beginning to define the standard or trying to figure out how to get your team to follow it, we can help! Reach out today—we’ll work with you to plan, prioritize, and deploy.
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Source of article: https://www.acadia-software.com/resources/3-manufacturing-trends-you-cant-afford-to-ignore/