Reasons Why You Should Improve Operational Risk Management in Manufacturing

September 10, 2024

Author: Sudeshna Ghosh

Basically, risks are of different types and many of them are braided together like reputational risks, financial risks, operational risks, third-party or supply chain risks, legal or compliance risks, and several others. Operational risks, generally, are viewed through the lens of safety management in an organization but for manufacturers, it is important to see the link between safety and operational risk management. The rationale for improving the operational risk management process is not only limited to safety but goes beyond it. There are many compelling tested and verified reasons to improve operational risk management in the manufacturing sector. 

In this article, we have discussed a few of those reasons that establish the fact that it is highly essential to improve the operational risk management processes to improve productivity and growth of an organization. 

A Comprehensive Overview of Operational Risk Management

Business risk management

Operational Risk Management (ORM) is a proactive and multifaceted approach to safeguarding an organization’s day-to-day operations. It serves as a strategic compass, guiding businesses through the ever-evolving landscape of internal and external risks. By systematically identifying, assessing, prioritizing, and mitigating potential threats, ORM empowers organizations to maintain resilience, protect their assets, and seize opportunities amidst uncertainty.

At its core, ORM focuses on the risks inherent in the execution of an organization’s core functions. These risks can stem from various sources, including human error, system failures, cyber threats, regulatory changes, and external events. By implementing robust ORM practices, businesses can minimize the likelihood and impact of operational disruptions, ensuring seamless continuity and sustainable growth.

Key Principles of Effective ORM

  1. Risk-Informed Decision Making:

    ORM provides a structured framework for making informed decisions by weighing the potential benefits against the associated risks. This approach enables organizations to strike a balance between risk-taking and risk mitigation, optimizing their risk appetite for competitive advantage.

  2. Proactive Risk Identification:

    Effective ORM requires a proactive mindset, constantly scanning the horizon for emerging risks and vulnerabilities. By anticipating potential threats, organizations can implement preventive measures and minimize the need for reactive crisis management.

  3. Continuous Monitoring and Adaptation:

    ORM is an ongoing process that demands constant vigilance and adaptation. Organizations must continuously monitor their risk landscape, assess the effectiveness of their mitigation strategies, and make necessary adjustments to stay ahead of evolving threats.

  4. Collaborative Risk Culture:

    Successful ORM relies on a shared understanding and commitment to risk management across all levels of the organization. By fostering a collaborative risk culture, businesses can leverage the collective knowledge and expertise of their employees to identify, assess, and mitigate operational risks.

The ORM Process: A Structured Approach

STEP

01
Risk Identification:

The first step in the ORM process involves systematically identifying potential risks that could disrupt operations. This includes analyzing internal processes, and human factors, as well as external factors such as market conditions, and environmental threats.

STEP

02
Risk Assessment:

Once risks have been identified, organizations must thoroughly assess their likelihood and potential impact. This comprehensive evaluation helps prioritize risks based on their severity, enabling the development of targeted and effective mitigation strategies.

STEP

03
Risk Mitigation:

Based on the risk assessment, organizations develop appropriate mitigation strategies. These strategies may include implement internal controls, enhance cybersecurity measures, or develop contingency plans for crisis scenarios.

STEP

04
Risk Monitoring:

Continuous monitoring is essential to ensure the effectiveness of ORM strategies. Organizations must regularly review their risk profiles, assess the performance of mitigation measures, and make necessary adjustments to adapt to changing circumstances.

The Benefits of Effective ORM

01
Enhanced Operational Resilience:
By proactively managing operational risks, organizations can minimize disruptions and maintain business continuity, even when faced with unexpected challenges.
02
Improved Strategic Decision Making:
ORM provides a structured framework for making informed decisions, allowing organizations to evaluate potential risks and rewards of their strategic actions.
03
Increased Efficiency and Productivity:
Identifying operational risks enables organizations to streamline processes, reduce waste, and optimize resource utilization across the board.
04
Strengthened Reputation and Stakeholder Trust:
Effective ORM showcases an organization's commitment to responsible risk management, fostering trust among key stakeholders.

Reasons to Improve Operational Risk Management Process 

By addressing various operational risks, organizations can achieve not only financial stability but also foster a culture of collaboration and resilience. Here are several compelling reasons to improve the ORM process:

Attain Financial Goals:

Align operational and financial data to minimize the impact of risks on financial performance.

Improve and Increase Collaboration:

Foster cooperation and joint risk management through a structured ORM framework.

Standardize Risk Assessment:

Apply uniform procedures and policies across all verticals to effectively mitigate operational risks.

Build a Risk Awareness Culture:

Establish visibility into control measures and integrate a risk mindset throughout the organization.

Enhance Regulatory Compliance:

Strengthen ORM processes to ensure adherence to industry regulations and reduce compliance-related risks.

Optimize Resource Allocation:

Direct resources strategically towards critical areas to enhance operational efficiency and productivity.

Reason 1: Attain Financial Goals 

There are many manufacturers who see the relationship between enhancing productivity and mitigating operational risks. But for better operational risk management, it is essential to move one step further and also see the relation in terms of financial performance. It is important to minimize the impact of operational risks on financial goals. Additionally, manufacturing companies must align operational data with financial data to analyze the financial impact of adverse events. 

Reason 2: Improve and Increase Collaboration 

If the financial goals are achieved, it has hard and quantifiable benefits. But implementing an operational risk management process also fetches soft benefits like improved cooperation and collaboration. This can furthermore help in the joint management of risks. The implementation of an operational risk management framework provides the catalyst as well as an incentive for organizations to also boost cross-functional collaboration. 

Reason 3:  Standardize Risk Assessment 

Manufacturing organizations, globally, understand that if they successfully mitigate operational risks, it improves the likelihood that corporate goals will be met. To mitigate operational risks successfully, the same procedures, policies, and risk management processes must be applied across all the verticals of the company. Best-in-class manufacturers have standardized risk quantification processes across the enterprise. 

Reason 4:  Build a Risk Awareness Culture 

To manage operational risks, it is very important to build a culture of risk awareness. This culture helps manufacturers to establish better visibility into control measures of operational risks. This can further help them to integrate a risk mindset, which further minimizes operational risks and their impact on financial and corporate objectives. 

Reason 5: Enhance Regulatory Compliance

Improving the operational risk management process is vital for ensuring compliance with industry standards and regulations. Manufacturers face numerous regulations regarding safety, environmental impact, and quality control. A robust ORM framework helps identify and mitigate compliance-related risks, reducing the likelihood of costly fines and reputational damage while fostering a culture of accountability within the organization.

Reason 6: Optimize Resource Allocation

An effective operational risk management process allows manufacturers to optimize resource allocation. By identifying and prioritizing risks, organizations can direct resources—such as time, personnel, and capital—toward critical areas needing attention. This strategic allocation enhances operational efficiency, minimizes waste, and maximizes productivity.

Case Study: Enhancing Operational Risk Management Strategies with Infiniti Research
Background:
A leading manufacturing company, specializing in consumer electronics, faced significant operational risks that threatened its production efficiency and financial performance. With a global supply chain and increasing regulatory pressures, the company recognized the need for a robust Operational Risk Management (ORM) strategy to mitigate potential disruptions and enhance resilience.
Solution 
Infiniti Research partnered with the client to develop a comprehensive ORM framework. The solutions included:
Risk Identification and Assessment: Conducting thorough audits and assessments to identify vulnerabilities within the company’s processes, systems, and external factors.
Implementation of Best Practices: Developing standardized risk management procedures across all departments to ensure consistent application of ORM practices.
Training and Awareness Programs: Launching employee training initiatives to foster a culture of risk awareness, equipping staff with the knowledge to recognize and respond to operational risks.
Continuous Monitoring: Establishing key risk indicators (KRIs) and monitoring systems to track risk exposure and effectiveness of mitigation strategies in real-time.
Results:  
The implementation of these ORM strategies led to significant improvements for the client:
Enhanced Operational Resilience: The company successfully minimized disruptions, ensuring smooth production processes even during unforeseen challenges.
Improved Decision-Making: With a structured framework in place, management could make informed decisions based on comprehensive risk assessments.
Increased Efficiency: Streamlined operations resulted in reduced waste and optimized resource utilization, contributing to overall productivity gains.
Strengthened Reputation: The commitment to effective risk management bolstered stakeholder trust, enhancing the company’s reputation in the market.
Through Infiniti Research’s targeted ORM solutions, the manufacturing company not only mitigated operational risks but also positioned itself for sustainable growth in a competitive landscape.

Real-World Examples

Here are some concise examples of operational risk management strategies implemented by real-world companies:

  • JPMorgan Chase: After the 2012 “London Whale” incident, the bank enhanced its internal controls and risk assessment procedures to strengthen its operational framework and prevent future risks.
  • Equifax: Following the 2017 data breach, Equifax improved its cybersecurity measures by conducting regular vulnerability assessments and enhancing incident response plans to mitigate risks from human error and system vulnerabilities.
  • Target: In response to a significant data breach in 2013, Target invested in advanced cybersecurity technologies and adopted proactive risk assessment methodologies, including regular security audits.
  • Wells Fargo: After various scandals, Wells Fargo strengthened its operational risk management by implementing rigorous compliance training and establishing a dedicated risk management team for regulatory adherence.
  • Toyota: To address supply chain disruptions, Toyota diversified its suppliers and developed contingency plans, investing in technology to monitor supply chain risks and enhance resilience.

These examples demonstrate how organizations effectively manage operational risks to ensure business continuity and protect their assets.

Conclusion

Improving operational risk management in manufacturing is essential for minimizing disruptions and ensuring long-term success. By using Key Risk Indicators (KRI) and a Risk Assessment Matrix, companies can proactively address potential issues such as data privacy and security risks and equipment failure. Regular reporting and monitoring alongside continuous risk assessments enable real-time identification and mitigation of risks. Integrating technology in risk management enhances predictive capabilities, ensuring more efficient operations. Adopting long-term risk management strategies not only improves resilience but also strengthens overall business performance in an increasingly competitive market. 

FAQs

Operational risk management in manufacturing refers to identifying, assessing, and mitigating risks that could disrupt operations. It involves utilizing tools like Key Risk Indicators (KRI) and a Risk Assessment Matrix to monitor potential threats, ensuring a proactive approach to risk prevention and minimization.

Key risks in manufacturing include data privacy and security risks, supply chain disruptions, equipment failure, regulatory compliance issues, and workforce safety. These risks can significantly impact production efficiency and overall business continuity if not managed effectively.

Manufacturing companies can mitigate risks by conducting continuous risk assessments and implementing long-term risk management strategies. Monitoring risks through reporting and monitoring systems, utilizing Key Risk Indicators (KRI), and applying technology in risk management can further strengthen their defense against operational disruptions.

Effective examples include the use of a Risk Assessment Matrix to prioritize and manage critical risks, leveraging AI for predictive maintenance to prevent equipment failure, and ensuring robust cybersecurity protocols to mitigate data privacy and security risks. Regular reporting and monitoring ensure that risks are identified and managed in real-time.

The future of operational risk management in manufacturing will increasingly rely on technology in risk management, such as AI and IoT for predictive analytics, enhancing continuous risk assessments. Companies will adopt more advanced long-term risk management strategies, and improved reporting and monitoring systems will enable quicker responses to emerging risks, especially in data security and operational efficiency.

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