Monthly Archives: March 2018

Accelerate and Achieve your Production Goals with Analytics

Companies often set aggressive business goals at the beginning of each year, only to find those targets unachievable or untraceable by Q4. The initial excitement slowly fades as the day-to-day business needs take priority. This is especially true for manufacturers.

With Q2 only a few days away, are you on track to meet your 2018 goals?Manufacturers need a way to make goals achievable and sustainable. That’s what a Production Control System (PCS) provides. Real-time production data, analytics, tracking systems and process control all work to make the goal not only possible, but easily achievable.

  • Production Visibility:

The key to setting realistic goals is understanding your production capacity, velocity and bottlenecks. ERP data points alone can only imply slowdowns on your shop and it may take weeks for them to come to light. Production control systems however deliver the operator monitoring and WIP dashboards to pinpoint obstacles and opportunities. Having confidence in your data is the best way to begin and the only way to achieve KPIs.

  • Select KPIs to track and measure progress:

Now that you have numbers you can trust you need to introduce a bit of creativity. Projecting opportunities and then strategizing an optimal path to success is all about your metrics. Establish a baseline by reviewing existing trends and immediately put in place the means for tracking success. Failure to do so leads to moving targets and a lack of urgency for meeting deadlines.

  • Make the goal visible to the company:

Visualizing and tracking progress builds collaboration and a sense of accomplishment for your business. Presenting the challenge to your team lets them know your company is forward thinking and trusts in their abilities to succeed. Set and celebrate milestones along the way and take pride in your team’s accomplishments.

  • Sustainability:

Don’t let success or failure be the end of the journey. Carry forward the momentum into the next project, quarter, year, etc. Now that you have set a culture of excellence in your organization it’s up to you to define how far you can go. Sustainable production control systems stay on your shop for years assuring your data collection is consistent and accurate. Granular insight into production lets you see what works and what doesn’t. Turn success into a standard, repeatable process.

 

Next Steps

There’s still time to get the right systems in place to achieve your 2018 goals. April is the final month of the CIMx Software 18 Free in 2018 promotion so now is your last chance to connect with the CIMx team about free installation. Contact CIMx to let a specialist review your needs and see how a Production Control System can make those goals achievable.

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How to Turn Production Data into Actionable Manufacturing Intelligence

There’s a critical difference between raw data and actionable manufacturing intelligence. Data is just information. Actionable manufacturing intelligence adds value. When provided to the right person at the right time, action can be taken and value added – that could mean higher throughput, lower costs, and more productivity.

Companies utilizing actionable intelligence find success in the marketplace. They have the flexibility and production agility modern manufacturers need.

The Morning Reports Sinkhole in your Production Cycle

For companies relying on spreadsheets, paper travelers and their ERP for production data, information is compiled at the end of the day and then shared in a morning report. A morning report is data, and not actionable intelligence.

The data in the morning report is often flawed, if not completely fictional. The ERP was never designed to collect production data, so patchwork and dubious methods are used to gather information. Employees pencil whip information on a traveler before clocking out for the day, or fudge numbers when memory fails. A coffee spill on a spreadsheet can ruin the data and leave you scrambling to decipher a smudge.

Manufacturers using data like this to track and control production are hurting themselves. Decisions are made on speculation using the best data available (data that was never very good in the first place). This leads to a lack of discipline and control in production. Waste and scrap increases, and problems stymie production velocity with no clear solution as management isn’t sure what happening on the shop floor.

Manufacturers need actionable manufacturing intelligence, and actionable manufacturing intelligence requires real-time production data.

The Key to Manufacturing Intelligence

The Quantum Production Control System (PCS) is designed to provide accurate and actionable real-time information on production.

Using Quantum and your current build books and work instructions, you can begin collecting real-time production data from your current processes and standard use of the system. Accurate updates and Work In Progress (WIP) reports are just a mouse click away. Capturing data is done automatically throughout production.

Take Action on Improved Production

Real-time data is actionable, while a morning report is nothing more than a review – a window into the past. With the PCS in place, real-time production data is fed to the right people at the right time to make a positive impact on production. Supervisors can see a problem occur, such as a machine going down or a late material shipment, and then take action to mitigate and solve the problem. Feedback loops at the work station provide rapid resolution to problems, keeping production on schedule.

Contact CIMx Software today and connect with our team to see how quickly Quantum can empower your production team with actionable manufacturing intelligence to accelerate productivity and eliminate waste for you. Ditch the spreadsheet and embrace efficiency in your processes with Quantum.

Process Improvement graph.

Use Your Data for Accurate Production Costs

For manufacturers, accurate estimates are critical to managing costs and margins. If estimates are based on guesswork: bids can be lost, delivery times missed or costs can spiral out of control. Too often, operators will pencil-whip work times on their way out the door rather than accurately tracking and recording their work. This skews the limited data available causing misinformed directives from the top.  When both the historical data and the analytics at the foundation of estimates are suspect, problems quietly grow costing the company money that has to be made up in additional production.

Turn Production Data into Profit

Accurate estimates require both clean historical data and production visibility, both of which are provided by the Quantum Production Control System (PCS). Let’s look at a few areas a PCS can enhance your estimates:

  • Accurate Labor and Production Data

Know who did what and for how long during production, and then turn that data into more precise estimates. The PCS automatically tracks labor and production through standard use of the system. This includes machine time and labor, so management can see how much time, effort, materials and parts are required to complete work. Over time, as accurate data is accumulated, the company can begin providing more accurate estimates and labor loading.

  • Identify and eliminate scrap

Scrap can turn profitable products into an expense for manufacturers, and yet many companies struggle to understand the cause. The production control system collects production data that reveals where and how scrap is generated. The PCS links the scrap to the work being done at the time it occurs. With this information, the manufacturer can either eliminate the root cause of scrap, or better estimate standard losses in production.

  • Focus on profitable work

Once you are tracking labor and production costs, leverage the data to identify and prioritize the most profitable work. Refine your gross manufacturing margin using production data to identify products and goods with a higher gross margin. With this information, you can make more profit on every sale and shipment. The company makes more and spends less.

Increasing Profit Velocity

Many companies look at a production control system to solve a specific problem such as a failed audit, late shipments, or poor visibility into Work in Progress (WIP). Even with the solution in place, the company finds more value in the critical data the system feeds to the sale and production cycle. With higher gross margins, accurate estimates, and control over scrap and production the company finds expenses go down and profits up.

If you’re ready to take control of production costs and enhance your profit on every product built, contact CIMx Software today to learn more about Quantum. Discover what a PCS can do for you.

How to Turn your KPIs into Profit and Production

There’s an old saying, “If you can measure it, you can manage it.”

Manufacturers with Production Control Systems (PCS) know the truth of that saying. With the PCS providing the real-time data and process control, these companies supercharge their Key Performance Indicators (KPIs) with real-time data to accurately track and measure shop floor progress. That real-time data turns KPIs from an instrument of observation to a tool for radically accelerating and sustaining production while generating profit.

Turn Raw Production Data into Efficient Operations

Here are four ways real-time data and KPIs deliver powerful benefits for manufacturers:

  • Accelerate and sustain continuous improvement programs.

Continuous improvement is critical, but many companies have difficulty maintaining progress once the program is over. New behaviors are difficult to maintain, and old habits die hard. KPIs allow the company and team members to monitor the progress. Your team can use that real-time data to support improvements long after the program is over. With everyone sharing the KPI and monitoring progress, collaboration increases and success is shared.

  • Benchmark performance to identify areas for improvement.

Use KPIs to benchmark and compare areas of the business. Identify underperforming areas and discover what works in areas of high-performance. With that insight, you’ll discover those slight adjustments that pay big dividends. For example, higher scrap and non-conformance rates at certain operations may indicate machines or tools that require maintenance, or a problem with a supplier. Target and eliminate the problems for a positive net effect across the production value chain.

  • Identify higher profit work

KPIs are an excellent way to evaluate production data in real-time, revealing the inefficiencies that cripple profit margins if left unchecked. For example, Estimated versus Actual production times, a common KPI, identify products that consume more resources than expected, delivering a lower profit. By focusing on higher-profit work, the company generates more revenue for less effort.

  • Evaluate planned workarounds

When an issue occurs in production, supervisors will implement planned workarounds that often result in more problems than they solve. KPIs monitor progress as the workaround is implemented. Evaluate the solution in real-time and implement additional changes as needed to maintain progress. With KPIs, the orders stay on schedule and ship dates aren’t missed.

Turn Real-time Data into Production and Profit

Most, if not all, manufacturers utilize Key Performance Indicators to monitor production. The difference for manufacturers with a Production Control System in place is the real-time data that fuels the KPI. Supervisors and management track and monitor production, accessing critical KPIs from anywhere. The PCS makes the company more agile, able to control production and manage work. The shop floor reacts to issues and opportunities as they happen, rather than studying events in a report a day later.

Contact CIMx today to see how Quantum can supercharge your KPIs and reports with real-time data to accelerate production and profit for your business.