Kurtis Patel | Why Operational Simplicity Improves Manufacturing Reliability
Kurtis Patel
Manufacturing systems tend to become more complex over time. New steps are added to solve specific problems, additional approvals are introduced to manage risk, and layers of oversight accumulate as organizations grow. While these changes are often well intentioned, they can reduce clarity and reliability if they are not reviewed carefully. According to Kurtis Patel, operational simplicity is one of the most effective ways to improve manufacturing reliability without sacrificing control.
Operational simplicity does not mean removing discipline or oversight. Instead, it means designing workflows that are easy to understand, repeat, and maintain. When processes are overly complex, teams often rely on workarounds to keep production moving. These workarounds introduce variability and make outcomes harder to predict.
Kurtis Patel notes that simpler systems make deviations easier to identify. When a process has a clear structure, teams can quickly recognize when something has changed or gone wrong. This improves troubleshooting and reduces downtime. It also makes training more effective, as new team members can follow documented procedures without relying on informal knowledge.
As manufacturing volume increases, complexity becomes more costly. Each additional step requires coordination, documentation, and communication. Over time, this increases the likelihood of misalignment across teams and shifts. Simpler processes scale more smoothly because they are easier to document, audit, and replicate.
Operational simplicity also supports better communication. When expectations are clear and workflows are straightforward, teams spend less time clarifying responsibilities and more time executing effectively. This alignment strengthens consistency across development, manufacturing, and quality functions.
From Kurtis Patel’s perspective, reliability is built through clarity. By focusing on essential steps and removing unnecessary complexity, manufacturing systems become more stable, predictable, and capable of supporting long-term growth.