How Small Errors Can Have Big Impacts in Manufacturing Industry

Think about an unassuming domino chain—perfectly balanced and completely in balance. Yet all it takes is to push one domino, and the entire line falls, resulting in unforeseen consequences. This domino effect is what every day looks like in manufacturing companies that fail to recognize the importance of work instruction software.

• Wasted materials and rework
  In 2022, a study by the National Association of Manufacturers (NAM) established that defects resulting from poor quality cost US manufacturers a whopping $223 billion annually, with rework being a significant factor.

• Product recalls and safety hazards
  The FDA listed over 300 medical device recalls for 2021 connected to manufacturing defects.

• Damaged brand reputation
  The loss of consumer confidence and brand loyalty due to a single product failure can translate into millions of dollars or pounds in losses.

These are a few possible consequences that even the slightest human mistake can produce in manufacturing. However, why do humans make so many mistakes in this high-pressure environment? That is what we will be answering in our Talygen Reviews.

That said, the solution lies in the essence of human endeavor and using the right tools. Furthermore, we are prone to fatigue, distraction, and knowledge deficits. Boredom and reduced concentration in such a case result from the monotony of the task, and complex instructions may need to be clarified or remembered. Moreover, new employees may require more experience and training, which would ensure that tasks are performed with no mistakes every time.

Manufacturers can substantially reduce the instances of human error and the consequences with work instruction software like Talygen.

Talygen: Minimizing Errors, Maximizing Impact

Talygen, as a work instruction software, operates on the principle that clear, consistent, and accessible information empowers workers to perform their tasks accurately and efficiently. It achieves this through a combination of features designed to address the root causes of human error

• Standardized work instructions
  The paper manuals are not always easy to understand. On the other hand, Talygen offers detailed, visual guidelines that are understandable and straightforward, even if a person is still in the learning or training phase or has little to no experience in the manufacturing industry. The work instruction software minimizes the chances of misunderstandings and ensures perfect communication and implementation of work instructions set by project managers.

• Real-time feedback
  Don’t wait until the end of a task to find a mistake. Self-correction is made possible because Talygen, the work instruction software, provides immediate feedback on task completion and thus prevents these errors from going down the line. This not only enhances the quality of the product but also creates a habit of continuous improvement among team members.

• Digital checklists
  The written paper checklist is easy to forget. Talygen’s checklists have all the essential steps, and there is no possibility of tasks not being omitted from the list. This, in turn, provides another level of safety and quality control in the production process if you have integrated work instruction software in your manufacturing operations.

• Data analytics
  Talygen’s work instruction software traces error patterns and points out areas for improvement. The data-based model allows manufacturers to preemptively neutralize potential issues before becoming problems, minimizing the potential of errors and associated costs.

Beyond Error Reduction: The Broader Benefits of Talygen

While minimizing human error is a significant benefit, Talygen’s work instruction software and how its impact extends far beyond that.

• Improved worker productivity
  Simple instructions with Talygen and workflows designed to ensure they are not time-consuming eliminate confusion and loss of time, leaving them to focus on completing tasks as quickly as possible.

  It is worth noting that a 2021 study by McKinsey & Co. revealed that digitizing work instructions can improve productivity by up to 25 percent in a manufacturing organization

• Enhanced worker training
  Talygen’s work instruction software acts as a training tool that facilitates the training of new employees and gives them the necessary knowledge and guidance to perform their work accordingly. However, this minimizes the chance of mistakes, speeds up onboarding, and lifts general skill levels.

• Boosted quality and safety
  Talygen improves the quality of product accuracy and safety in the workplace as it minimizes errors and ensures consistency in task completion. This caters to the clients’ needs and ensures workers are protected from all hazards.