Practical Strategies to Drive Operational Improvement

This article appeared in the October 2025 issue of MiMfg Magazine. Read the full issue and find past issues online.

You are likely seeing signs of increased business, whether it’s demand signals like hosting client visits for new programs or you already have orders in hand. If not, buckle up — it’s coming.

The impact of policy actions to rebuild U.S. manufacturing is visible. The second quarter of 2025 noticeably picked up and the upturn is significant in the second half of the year. Machine builders, automation integrators, robot and PLC programmers and electrical contractors are busy on the plant floor. Production, maintenance and manufacturing engineering teams are going full tilt. Requests are coming in to assist with new lines, automation deployments and transformation projects over the holidays. These are exciting times, but you may be wondering how to get it all done when you are running 5x24 or more.

Here are four strategies to consider for enabling increased output or if you are simply looking to drive efficiencies and improved cash flow with your current operations.

1. Assess and upgrade your digital infrastructure. Most expansion and transformation initiatives require upfront work and additional time in the work plan. Networks are outdated, machines are not connected, PLCs require upgrades and servers need to be refreshed or replaced. Get a head start and make sure you are ready.
2. Take a fresh look at intelligent manufacturing solutions and revisit options if it’s been more than a year. You are already producing valuable machine data on your PLCs and you don’t need expensive sensors or integration software to leverage it. Platforms are available that deliver powerful insights in days to weeks, not months. Cycle time and OEE improvements, more efficient start-ups and model changes, early warning signs to head off unexpected outages and higher availability are all within reach. These improvements go straight to the bottom line — take advantage of it.
3. Optimize your service and incident management. You can start with an easy-to-deploy Incident Management subscription to capture, time stamp, triage and resolve issues that deliver valuable insights. This data can help you optimize scheduling and skill levels to close tickets and issues faster. Conditional alerts and remote monitoring are effective, especially for night shifts, with 24x7 dispatch capability available based on incident severity thresholds. The outcome is reduced time to resolution to improve asset utilization and increase jobs per hour.
4. Consider ways you can transform your Operational Technology (OT) support model. We all know the challenges in finding, hiring and retaining technical talent. Changing technologies and attrition compound that issue. Plant floor support, including PLC, network, MES, OT and security engineers can be delivered in an as-a-service model with dedicated, fractional or even per-event service models with SLAs. Another approach is to leverage a capable, U.S.-based, operations center provider to secure 24/7 critical situation support that works in concert with on-site teams. Get fresh ideas on ways to support your operations.

You don’t need to tackle all four strategies, certainly not at the same time. A quick assessment, prioritized list of initiatives based on ROI and a flexible roadmap would be a solid foundation. Now is a good time to explore new ways to support your business.

About the Author

Jim Fatur is a Vice President with Troy-based CoffeeTree Group. He may be reached at 248-396-7090 or jimfatur@coffeetreegroup.com.

CoffeeTree Group is an MMA Basic Associate Member and has been an MMA member company since May 2025.