When there's a sudden surge in orders, it's a challenging but opportune time to tighten controls and standardize processes. Implementing low-cost automation can quickly introduce automated controls and deskill some critical operations. Strengthening the gating system is a good intermediate measure for short-term surges, but it may require adding skilled manpower judiciously. If the surge has long-term potential, it's advisable to invest in debottlenecking and comprehensive automated controls. This proactive approach ensures sustained efficiency and scalability to meet ongoing demand effectively.

To prioritize quality control measures during a surge in manufacturing orders, focus on establishing robust, scalable processes, increasing inspection points at critical stages, prioritizing training for staff, utilizing real-time monitoring systems, clearly communicating quality expectations, and actively identifying and addressing potential bottlenecks to maintain high standards even under pressure. Review and strengthen existing quality control processes By (BPM)

Stick to the Basics: Make sure your team follows the processes that have worked before. Consistency is your friend. Bring in Help: If the workload is too much, hire extra hands to keep the quality on point. Use Technology: Tools that track and check quality can lighten the load. Stay Connected: Keep communication open and act fast when challenges arise.

One thing I have found helpful during those times when we had surge in demand is to increase the frequency of engaging the team. Using not more than 5mins at the start of their various shifts to remind them of the Quality and Safety standards which they already know help to maintain the quality of our products and also ensure a safe workplace.

When we have had an avalanche of orders, in addition to the aforementioned strategies that we have put into action, we have extended additional work shifts with temporarily hired personnel.