Manufacturing

7 challenges in the manufacturing industry and strategies to turn the tide

Sven Persoone

11 Mins
01/10/2024

Companies in the manufacturing industry today do not have it easy. In fact, they are extremely vulnerable as economic pressures persist. Moreover, industrial companies face numerous challenges that can undermine their operational and financial stability. This article takes a closer look at the current economic situation in the sector and highlights the main risk management challenges.

Current economic situation

Some 180,000 companies operate in the manufacturing industry in Belgium. Most of them are small companies. Some may even have no staff, and just over 4% have more than 50 employees. The larger industrial companies are quite healthy according to traditional financial indicators, but they are not really resilient according to GraydonCreditsafe's Resilience Indicator.

The Resilience Indicator calculates the reserves held by a company over and above those needed to cover normal operations and normally predictable risks. The indicator thus assesses the resilience or shock resistance of an organisation. The bottom row in the table shows that 41.9% of those large companies are not resilient and run into trouble when an unexpected setback occurs. Note that the far-right segment contains as many as 36% financially sound companies. At least according to traditional financial analysis.

(more than 50 employees)

Manufacturing 9-grid > 50 employees

All companies in the manufacturing industry face an uncertain economic environment, characterised by fluctuating demand and price volatility. This uncertainty is compounded by geopolitical tensions and changes in trade policies, which directly affect supply chains and production costs.

Challenges

1. Pre-financing and low margins

Many companies in the sector have to pre-finance significant amounts to buy materials and components even before the final products are sold and paid for. Combined with the generally low margins in the sector, this puts pressure on cash flow.

The challenge is compounded by the need to stay competitive without overcharging customers. In any case, well-balanced credit management is not a luxury in the sector, but a crucial process.

A practical example

A European auto parts manufacturer had to invest in sophisticated equipment to comply with new emission standards. Because of the high upfront costs associated with R&D and implementation of advanced emission reduction technologies, the company looked at leasing options and negotiated longer payment terms with suppliers to manage cash flow. These strategies helped reduce initial financial pressures without significantly increasing prices.

2. Failing supply chains

Dependence on global and often complex supply chains makes companies vulnerable to disruptions. These usually involve external factors such as political unrest, natural disasters or pandemics such as COVID-19 that companies cannot control. This can range from delays due to logistics problems to scarcity of essential materials. It then leads to production interruptions or even shutdowns and increased costs.

A real-life example

Attacks by Houthi rebels have severely disrupted shipping traffic in the Red Sea. As much as 12 per cent of global trade usually passes through the Red Sea and Suez Canal. Out of safety, a lot of shipping companies were forced to make a diversion past the Cape of Good Hope. It extended sailing time by about 10 to 15 days and has sent container shipping rates soaring.

Challenges in the manufacturing industry - failing supply chains

It is the second incident in the region in just a few years. In 2021, one of the largest container ships was stuck in the Suez Canal for six days, which thoroughly disrupted trade between Asia and Europe and vice versa. 

During the COVID-19 pandemic, many manufacturers experienced significant supply chain disruptions. A well-known case is that of a global player in the electronics industry, whose production relied on components from several Asian countries. To mitigate future risks, the company talked to multiple suppliers and entered into new agreements. It also invested in technology for better forecasting and real-time supply chain tracking.

3. Uncertain economy

Economic volatility, such as changing consumer demand and unpredictable economic cycles, creates an unstable market. This requires companies to be flexible and adaptive, but also to carefully balance between expansion and investment or cost-cutting and downsizing. It does not make planning and budgeting easy.

A real-life example

A company in the building materials industry saw a sharp drop in demand during the 2008 economic recession. The company survived by diversifying its product lines, entering new markets and investing more in marketing during the downturn. It enabled the company to be better positioned when the market finally recovered.

4. Technological lag and innovation pressure

Rapid technological advances constantly force companies to question their production processes and innovate products. Companies that lag behind in this can lose their competitive edge, leading to reduced market share and potential failure.

A real-life example

Eastman Kodak, once a dominant player in the photography and film industry, did not immediately see a threat in the digital camera. It swallowed a significant drop in demand for their traditional products, especially when Apple launched its iPhone. Eastman Kodak was no longer able to change the giant organisation's course anymore and eventually even went bankrupt. Competitors that did innovate in time quickly took over the market share. Many tech companies, meanwhile, are investing heavily in R&D to maintain their place at the forefront.

5. Environmental legislation and sustainability obligations

Stricter environmental legislation can lead to higher operating costs for companies that do not comply with new standards. European laws and regulations around ESG present companies with huge challenges and additional investments in sustainability. 

We refer again in the table below to the Resilience Indicator, which we have linked to the ESG Indicator. The ESG Indicator shows how a company scores on the themes of environment, social and governance. Analysis shows that 7.99% of companies in the manufacturing industry still have a long way to go in this area (segment at the bottom left of the table). They are not ESG-ready at all, nor do they have the investment capacity to finance the transition autonomously. These companies are likely to run into trouble and may even be doomed.

Turning a blind eye to these new trends and regulations is not the way forward. Manufacturers need to understand and contribute toward the new European vision for sustainability and in return also reap the benefits that it offers. Especially, with regards to how consumers are now loyal to brands that adopt sustainable measures and base their purchase decisions on the environmental and social impact of the products.

A real-life example

Many chemical production companies must make substantial investments to adapt their plants to new environmental regulations.

Manufacturing 9-grid > resilience - ESG

Not complying with these regulations can lead to fines and a damaged reputation, which could ultimately threaten the continuity of the company.

Tesla, in turn, has benefited from this increased focus on sustainability and it is evident in how they’ve emerged as the most popular electric vehicle brand in recent years.

6. Volatility of raw material prices

Fluctuations in raw material prices can have a direct impact on production costs. Companies that rely heavily on specific raw materials are particularly vulnerable to these fluctuations.

A real-life example

An automaker experienced severe fluctuations in steel prices in the early 2000s due to international trade conflicts. It increased production costs, put pressure on margins, and threatened financial stability. This came at a time when automotive manufacturers were already facing a slack sales market, and it was difficult to pass on the costs to consumers by increasing the pricing.

Challenges in the manufacturing industry - labour market

7. Labour market challenges

Finding and retaining qualified staff is an ongoing challenge. Especially in high-tech sectors. A shortage of skilled labour can lead to delays in production and reduced product quality.

A real-life example

A technology company in the semiconductor industry was struggling to attract enough qualified engineers. It led to delays in the development of new products and loss of market share to competitors with better R&D capabilities. A lot of companies - not only in the technology sector - are already investing in training programs and collaborations with schools and universities to maintain the influx of qualified personnel.

Risk management strategies

All these elements show that it is essential for companies in the manufacturing industry to recognise a wide range of potential challenges. They also need to proactively develop strategies to ensure business continuity. It requires an integrated approach to risk management, strategic planning, and continuous evaluation of both internal and external factors.

The implementation of effective risk management strategies, such as increasing supplier diversity and optimizing financing structures, will play a crucial role in the stabilisation and growth of the companies in the sector.

Conclusion

The manufacturing sector faces significant challenges, but with the right strategies, companies can effectively manage risks and protect their financial stability. In a rapidly evolving world, the ability to adapt swiftly and stay ahead of the curve is more crucial than ever.

Wondering how GraydonCreditsafe can help you with this? Then contact us right away for a live demo of our online platform.


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