Production process delays are a long term risk that any and all businesses face. If you have a product to deliver on time, you’re going to need to produce it before it can be shipped out to anyone. 

And if this production process is slow, inefficient, and seemingly a non-starter, you’re not going to meet these important deadlines. But what’s at fault here? What’s really causing a delay within your production process? 

It could be a number of things, and that’s why you need to investigate. Whether you have the means to carry out your own manufacturing and production, or you work with a third party manufacturer, delays can arise from causes like these. 

Your Supplier is Late with an Order

You’re not entirely responsible for your own supply chain. And because of that, you need to rely on the timekeeping and stock management of other vendors within the chain. 

Thankfully, 99% of the time that works out just fine. However, every now and then, your supplier is going to send you a message about a delay they’re currently experiencing – and what that means for you.  

Long story short? It means you’re not going to get your order on time, whether it’s critical components required within your manufacturing, replacement parts needed for a machine, or staff uniform or PPE that’s essential to working safely. 

How to prevent supplier issues

1. Come up with an order schedule

If you work by only ordering parts and materials as and when they’re needed, and you’ve experienced more than a handful of delays throughout the year, this just-in-time supply might not be suitable for you. 

You might need to work with an order schedule instead. Give yourself a strict rota to work from, where you’re ordering certain supplies according to a set cycle. Fine materials on the first Monday of the month, PPE on the second Thursday, etc.

And to prevent overstocking, you can use an order schedule alongside just-in-time ordering. Anything you don’t run out of too often can be ordered as and when, as you’re more likely to be aware of when it’s running low and have time to react. 

2. Have one or two backup suppliers

Working with just the one supplier is a good way to keep your costs low. You’re not ordering all over the place, and you’re working on creating a long term relationship that can lead to discounts over time. 

However, you will need a backup option to turn to when your main supplier isn’t able to fulfil your request. And that means finding one or two other vendors who you can maintain a casual order schedule with. 

This way, if your main supplier doesn’t have something in stock, it’s no worry. You’ve got a couple of backup suppliers there, and either or both of them may have it in stock. 

You’ve Missed a Maintenance Check

It’s easy to do, but it’s not the sort of thing you want to happen more than once. And if it does, your machines could start dropping one by one. 

You might not even discover the reason why until it’s too late to prevent costly repairs, and simply because the maintenance schedule wasn’t kept up to date. 

You need to regularly check in with your machinery, fine tune the inner system, make sure it’s clean, and then keep a record of what work was done, and if there are any risks to keep an eye on. 

Machines Have Dirt and Grime Build-Ups

If you don’t commit to a cleaning schedule, your machinery is going to suffer from dirt and grime build-ups. You even risk issues with dust collections, which can result in factory fires if the machine in question requires a high working temperature. 

A factory boiler, for example, can clog up with dust over time. Internal components like a Diamond Power soot blower are crucial for removing residue like soot before it can collect, ensuring it’s actually wicked out of the system before it has the chance to cause overheating. 

There’s Been a Design Change at the Last Minute

And when there’s a design change at such a late point in the production process, it typically means the factory has to start all over again! 

Avoid late changes by revising the design before production work starts, which means going through a proper product design process first. 

There’s an Issue at Customs

Customs issues tend to happen at the worst possible times. 

After all, as it’s usually a lack of attention to detail that causes customs delays, you’re already likely to be dealing with a lot of stress in the first place!

And now your supplies, parts, and equipment are being held at customs until you either pay up or submit the right documentation. 

What can cause clearance delays?

There are quite a few common customs clearance issues you should be aware of, including:

• Unpaid, or improperly paid, custom fees
• Shipment value hasn’t been reported properly
• Import tariff changes that require further payment
• The paperwork isn’t quite right (i.e., a document is missing, or there’s not enough detail)

Customs will always withhold shipments that don’t meet these strict requirements, and can often do so for indefinite periods of time. As such, it’s incredibly important to know ahead of time what customs handlers need to see for easy, plain sailing. 

Get Your Production Process Back on Track

Manufacturing delays aren’t all that fun to deal with. Downtime can happen at any point in the process, and this could mean your products don’t reach market shelves, or a customer’s door, at the right time. 

This could lead to a loss in sales, profit, and customer trust, all of which can be hard for a business to recover from. 

So, make sure you’re up to date on your manufacturing maintenance, cleaning, and safety. Make sure you’re aware of customs rules you have to meet. And if there’s going to be a design change, try to provide as much notice as possible.