Starting production is more than just buying machines
Whether you’re making garments, electronics, plastic parts, or packaging materials — the way you set up your production floor directly affects your cost, quality, and safety.
This guide walks you through what a strong manufacturing setup looks like — across infrastructure, workforce, equipment, layout, safety, and operations.
1. Choosing the Right Machinery — Don’t Just Go by Cost
Key questions before buying:
What volume do you plan to produce per day?
Will the machine work for multiple product types or just one?
Is local after-sales service available?
What’s the downtime and maintenance cycle?
💡 Tip: Always compare power usage, output speed, and compatibility with raw materials before buying.
2. Workforce Planning — The Right Mix of Skill & Scale
Typical categories:
Operators – Machine handling
Helpers – Loading/unloading, packaging
Supervisors – Daily output, quality control
Technicians – Repair & maintenance
Account/Admin – Purchase records, salaries, compliance
For each shift, maintain a 2:1 ratio of unskilled to semi-skilled workers unless machinery demands higher expertise.
3. Factory Layout & Workflow Design
Poor layout = wasted time + unsafe movement + lower output
Design your factory to minimize:
Material movement between stations
Crossing paths of input/output
Worker crowding or idle time
Four Key Zones:
Raw material storage
Processing / Machine zone
Finished goods & QC
Packaging & dispatch
Use color-coded markings, designated storage racks, and safety signage throughout.
4. Shift Planning & Daily Operations
Set these 3 daily checklists:
Morning Startup: Machine warmup, oiling, power check, safety gear
Mid-shift QC: Random sampling of items produced
End-of-day log: Output, downtime, repairs, manpower status
📝 Maintain registers or use basic Excel sheets for production logs.
5. Safety Protocols You Cannot Skip
Every MSME must ensure basic industrial safety. Here’s what you need:
💡 Install signage near machines: “Do Not Touch”, “Use Safety Gear”, “Emergency Exit”
6. Preventive Maintenance — Save Lakhs in Breakdown Costs
7. Simple Tech That Can Boost Your Factory's Efficiency
Even if you aren’t running a smart factory, these tools help MSMEs:
🔧 Automation Tip: Even one auto-packing machine or quality scanner can reduce manpower and errors.
8. Incoming Material to Outgoing Dispatch — Flow Management
Define a clear SOP (Standard Operating Procedure) for:
Raw material inward → record batch number
Intermediate storage → label semi-finished goods
Finished goods → QC → packaging → inventory tagging → dispatch
This minimizes confusion, spoilage, and returns.
What stage are you in — setup, trial run, or already producing? What challenges are you facing in machine selection or worker planning?
Share your thoughts in the comments or start a thread at Manthan.