How Can We Effectively Communicate the Financial Impact to Machine Operators?

Hi, I work in a manufacturing company. For quite some time, we have been observing that the operators working at machines that provide us with raw material for another product are not delivering the correct quality of material. As a result, many of our consignments have been rejected. We have already tried speaking to the HODs and the shift in charge, but to no avail. Now, we have been asked to communicate directly with the operators so that they understand the company's products were rejected because our raw material was not finished properly, leading to a significant financial loss. Could you please advise on what kind of communication tool I can use to engage with the operator-level employees? I need to convey to them the financial impact of their actions on the overall company. Since this is a manufacturing plant, electronic media displays are not feasible.

Addressing Product Rejection in Manufacturing

Increase in rejection of finished products could be due to many reasons. Have you investigated the causes of rejection? What was the percentage of rejection before, and what is the percentage now? Secondly, at what stage of the production process are quality issues occurring most frequently? Have you conducted a Pareto Analysis of the rejections? When speaking to the operators, ensure you are armed with proper data. Simply giving motivational lectures will not suffice.

Furthermore, Heads of Departments (HODs) are accountable for the output from their respective departments. Why are they distancing themselves? Why is the Production Manager remaining silent? Has he looked into the causes of rejection? When addressing the rejection issue, involve the HOD in the resolution. Communicating directly with the operators could be seen as bypassing the Supervisors and Shift in charge, undermining their authority further.

Possible Causes of Rejection

a) Poor quality raw materials
b) Inadequate machine maintenance
c) Lack of calibration for tools and instruments
d) Untrained staff
e) Excessive production pressure on personnel
f) Lack of intermediate quality checks
g) Absence of motivation from the Production Manager
h) Demotivation of the Production Manager himself - who motivates him?
i) Insufficient technical competence of the Shift in charge, Production Manager, etc.

While you emphasized communication in your previous message, it's essential to lay the groundwork for effective communication. Incomplete communication could render your efforts rhetorical, setting you back to the starting point.

Thanks,

Dinesh Divekar