You may need to start scaling operations to meet new productivity goals, but that’s no small task. Scaling can be costly, unwieldy, and disruptive when done wrong.
Here, we’re going to look at how you can do it quickly and effectively, without putting your business at too much risk.
1. Work out your current production capacity
Before scaling, businesses need a clear understanding of what their current operation can realistically handle. This means reviewing equipment capacity, staffing levels, production speed, waste rates, supplier reliability, storage space, and quality issues. Many companies make the mistake of accepting larger orders before they know whether they’re really able to handle them or not. With an in-depth capacity audit, you can see where potential bottlenecks might arise, whether it’s in the machinery processes, packaging, inspections, or even your supply of raw materials. Scaling your production might sometimes be a more precise operation than a wide-reaching boost in scale, and an audit can make sure that you’re spending your money where it’s going to make the most difference.
2. Improve your hiring and onboarding practices
If you do need to significantly scale any of the processes that go into production, then the likelihood is that you’re going to need to hire more people to support the increased capacity. Whether you need warehouse workers, packers, machine operators, or otherwise, you need to find a direct link to those looking to build careers in manufacturing and operations. For instance, attending university career days can be just as helpful in finding entry-level staff as posting ads in the local papers or jobs boards. Take the time to streamline your hiring and onboarding processes as best as possible, allowing you to grow your team to meet your new demands without rushing them into positions that they’re not ready to fill.
3. Standardise your processes before you scale them
When you have a work process that’s working well, you need to make sure that you make it repeatable. Hiring more people and expanding your production line without having a clearly standardised method of completing the processes that make it up can lead it up to your team finding the way that works for them, which isn’t always going to be the fastest or most error-free. Standard operating procedures (SOPs), batch records, checklists, training guides, and inspection points help ensure that products are made the same way every time. This is especially important in industries such as food, chemicals, cosmetics, engineering, and pharmaceuticals, where small inconsistencies can create safety or compliance problems.
4. Know where automation might remove bottlenecks
Integrating new technologies to automate certain processes can help businesses scale more quickly and cost-effectively than always having to hire new blood, but when it’s rushed and implemented too widely, it can leave the business way more open to failure on a systemic level, which can shut production right down. Keep your automation choices manageable by targeting them on repetitive, time-consuming, or error-prone tasks. For example, automated filling, labelling, inventory tracking, inspection systems, or material handling can increase output while improving consistency. Automation is great when it’s able to remove bottlenecks, but not when it’s being widely implemented across flawed processes where it might only compound existing problems.
5. Outsource specialised processes that can be too complex or costly to scale
You might currently have some processes that require a specific level of expertise or complex machinery that you’re able to handle right now, but if you need to expand your production, then it might quickly become too expensive to continue to justify. Some processes may require specialist equipment, technical knowledge, safety controls, regulatory awareness, or costly materials handling. Outsourcing these stages can help you scale much faster without having to put a lot more towards your capital investment. Working with experts in polymer dispersions, for instance, can be a lot more cost-effective than trying to bring it in-house after all. Eventually, with time, and when you have been able to scale cost-effectively to the point where you can afford it, you may choose to integrate your outsourced labour, but you don’t have to rush to do it when it may jeopardise the health of the business.
6. Strengthen your supplier management
Where your business does have to rely on third-party providers, of course, you should make sure that they’re as reliable as possible and, what’s more, able to fully support your increased needs as you scale. After all, even if your processes are effectively scaled, you still can’t grow your production capacity if you’re not able to get your hands on the raw materials, components, packaging, or spare parts you might need. As such, you should take the time to review your suppliers carefully before expansion. Companies should identify critical materials, qualify backup suppliers, negotiate realistic lead times, and manage their inventory more effectively with the right software systems.
7. Protect your quality control
The greatest risk of scaling too fast is that you’re not able to maintain a consistent quality in your products. When businesses scale quickly, inspection standards can slip because teams are focused on speed. This creates the risk of defects, recalls, complaints, waste, and reputational damage. As such, quality checks must be built into the process before you start scaling it. Leaving it to the end is the perfect way to see standards slipping. As production expands, make sure that all new team members are trained in quality control and that checks are integrated into more steps of the production line. It’s a small interruption to ensure much greater production capacity overall.
Some risk is inherent to all scaling operations. You need to ensure that you’re able to make the money to justify the increased scope and scale of your production. However, reducing costs and improving efficiency with the tips above can help you do just that.
