The risk of the on-site leader arbitrarily changing the process and lowering the yield

Understanding the On-Site Leader’s Role

The role of an on-site leader is crucial within any production or manufacturing environment.
They are responsible for overseeing operations, ensuring that processes run smoothly, and that the team meets its targets efficiently.
However, an on-site leader’s influence can extend beyond just management; they have the power to make significant decisions that can affect the entire production process.
In some cases, this capability can lead to situations where an on-site leader makes arbitrary changes to the process, potentially affecting the yield negatively.

The Importance of Following Established Processes

Processes in a manufacturing environment are meticulously crafted and refined over time to ensure high productivity and quality.
These processes are designed with input from experienced engineers, quality assurance teams, and other stakeholders.
They consider a multitude of factors, including the properties of materials, efficiency of machinery, and skills of the workforce.
Deviating from these established processes, even with good intentions, can lead to a cascade of issues that ultimately reduce the quality and quantity of the yield.

Why Changes May Occur

On-site leaders might feel compelled to amend process guidelines for various reasons.
They may encounter immediate challenges or disruptions during production that do not have an obvious solution, such as equipment malfunctions or sudden changes in raw materials.
In other cases, external pressures, like tight deadlines, might push a leader to make on-the-spot decisions in an attempt to expedite processes.
However, without proper analysis and testing, these changes can inadvertently introduce errors and inefficiencies.

Potential Consequences of Arbitrary Changes

Impact on Yield

When an on-site leader makes unsanctioned changes to the process, even minor tweaks can lead to significant discrepancies in output.
The changes could result in downtimes, increased waste, or compromised product quality, all of which contribute to a lower yield.
Ultimately, if issues arise from these changes, the loss in terms of productivity and wasted resources can be substantial.

Compromising Quality

Yield is not the only factor at risk.
Product quality often suffers when established processes are not adhered to.
Quality control measures aligned with original processes may no longer catch defects accurately, resulting in more errors slipping through to the final product.
This, in turn, can damage the company’s reputation and lead to dissatisfied customers.

Employee Morale and Organizational Impact

Repeated changes in process can also negatively affect employee morale.
Workers on the line rely on consistency and predictability to perform at their best.
Frequent process changes can lead to confusion, frustration, and even safety hazards if employees are unsure of the new protocols or equipment settings.
Moreover, it can create a culture where employees feel their input and experience are undervalued, leading to disengagement.

Preventing Arbitrary Changes

Establish Clear Communication Channels

One effective way to avoid arbitrary changes is to establish clear, efficient communication channels within the organization.
This helps ensure that any suggested changes by an on-site leader are communicated to the relevant departments, such as quality assurance or engineering, for evaluation and approval.
This collaborative approach helps in maintaining process integrity while still allowing for innovation and improvements.

Continuous Training and Development

Providing ongoing training and development opportunities for on-site leaders and their teams can significantly reduce the temptation or perceived need to change processes arbitrarily.
Through exposure to the latest industry standards and practices, on-site leaders can gain a better understanding of why processes are structured as they are and the potential repercussions of changing them without thorough analysis.

Implement Regular Process Audits

Conducting regular audits of processes and involving the on-site leader in these evaluations can aid in identifying potential areas for improvement.
These audits can help strike a balance between rigid adherence to processes and adaptive changes that bring about positive outcomes, ensuring that improvements are strategically implemented and tested, rather than on a whim.

Conclusion

The on-site leader plays a pivotal role in maintaining the efficiency and quality of production processes.
While there can be valid reasons for wanting to adjust existing procedures, doing so without a comprehensive evaluation can have detrimental effects on yield, product quality, and employee satisfaction.
By maintaining open communication, encouraging continuous learning, and conducting regular audits, organizations can empower on-site leaders to contribute to improvements in a controlled and effective manner.
This approach ensures that any changes enhance rather than hinder overall productivity and yield.