Building a manufacturing dream team

Everyone who calls manufacturing a career tries each day to get better at their jobs, to better serve their customers and their markets.

10/07/2012


My favorite statistic from the 2012 Summer Olympics: 85 different countries won medals at the game in London, from the 104 medals captured by the United States to the single bronze medals won by Morocco, Saudi Arabia, Kuwait, Bahrain, Afghanistan, Tajikistan, and Hong Kong. Not every nation can win, but 204 nations competed and more than 40% walked away with something to share with the home folks.

There’s a lot of pride in those achievements, and that pride is universal. When you saw a close-up of an athlete’s smile after achieving something amazing on that global stage, could you ever be sure what country the athlete came from? A smile is pretty much the same everywhere. It is the similarities among all of the athletes of the world, and not their differences, that make the Olympics truly special.

That can be said about manufacturing around the world as well. Not everyone has the infrastructure, the investment, the education, or the talent to compete with the world’s manufacturing powers. Everyone who calls manufacturing a career tries each day to get better at their jobs, to better serve their customers and their markets. Their willingness to compete deserves our respect and our admiration.

Once the workday begins, your job is to win the day—with better productivity, fewer lost workdays due to accidents, and the highest quality products on the market. To do that, you need three things: a manufacturing plan, a training schedule that turns that plan into consistent productivity, and talent. It is that final element that is in increasingly short supply.

No one in manufacturing needs to have the skills gap explained to them, and it does appear both major party candidates for president and the popular media finally have caught on to the issue. This is not about creating jobs; the jobs are there, waiting to be filled. This is about the failure of schools, government, potential workers, and especially manufacturing as an industry to fully grasp the problem and create dynamic solutions to address the issue. If we started today with a comprehensive solution to the skills gap issue and funded it fully with a combination of public and private funds, it will be five years before we fully realize its benefit. That’s five years where we won’t have the people we need to maintain and grow our manufacturing base.

Put in context, another entire Summer Olympics will have come and gone in Rio de Janeiro before we start to see improvement. And that’s if we start today.

So while a national solution eludes us, what can each manufacturing plant do? Let’s go back to our three basics:

  • A manufacturing plan: Are you measuring all you consume in raw materials each day—including energy? Do you have your workstations set up to enable peak efficiency? Are you driving that efficiency throughout your supply chain? Do you value safety above all other considerations?

  • Training: Very simply, do your people know what is expected of them individually, and do they have the tools to achieve those goals? Do they also understand how what they do helps the plant achieve all of the goals that are part of the manufacturing plan?

  • Talent: We’ve talked about having enough talent, but do we have the right talent? Put another way, if you had to start all over again from scratch, would you keep the same team?

This is what the U.S. Olympics basketball teams do every four years. The coaches are charged with finding not just the best players, but the best players who can work together to achieve the goal of winning. Talent is a significant component of that equation, but so is the ability to subjugate the personal goals to achieve what is best for the team.

There’s another side to this issue, of course: would your team want to keep playing for you? Are you delivering a clear vision and a strong sense of teamwork? Are you valuing the individual talent and surrounding it with similar talent? Not everyone is LeBron James; everyone can be a valuable member of the team.

This is an interesting time to be in manufacturing. If I were a skilled manufacturing worker I’d be keeping my eyes peeled for ways to enhance my career arc, and if I were a plant manager I’d be looking to recruit more talent from other plants, regionally and nationally. There’s no doubt the best manufacturers aren’t waiting for someone else’s solution; they are creating their own Dream Team, and making it better every day.

In manufacturing, as in basketball, you can build a Dream Team if you can articulate the goals, find the talent and get them to execute your vision for excellence.



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
Maintenance & Safety
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me