Monthly Archives: July 2018

The Risk of Manufacturing Automation

Ed Deaton | CIMx Software

Standardized processes and machine automation are the driving forces behind modern manufacturing in the United States. These tools maintain order across the shop floor and keep work on schedule. This structure is essential to eliminating waste and generating profit, however, no process is without risk.

The threat from automation and well-structured processes arise when we become overly reliant on them. This reliance leads to blind spots and complacency across the company.


The Solution: Real-Time Production Control

Spot red flags in real-time with Production Dashboards designed to keep your orders on-schedule and under budget. Increase production with digital work packets and enforce Quality with automatic tolerance checks and sequential sign-offs.

Leverage a complete Manufacturing Execution System (MES) to empower your employees to increase both Quality and production rates. Your team is your most valuable asset and the right MES will give them the tools they need to succeed.

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Creating a Culture of Compliance

Ed Deaton | CIMx Software

Catch and resolve these common audit issues before the regulators do.

If you’re in the manufacturing industry you understand how essential auditing is to your company’s success. The amount of resources required to report multiple times a year may be frustrating, but their value cannot be overstated.

That said; you hate everything about them.

Here are three tips for getting ahead of your inspection and receiving the most value out of every audit.

 


1. Risk Avoidance

Audits are all about mitigating risk. Whether it’s risk to your employees, your customers or your bottom line; audits exist to keep your shop on schedule, compliant and safe. Inconsistencies in processes, Operator error and record keeping are among the most common issues reported during internal reviews.

To mitigate these risks you need to both control how work is executed and collect the right data as consistently as possible.

Leverage the digital work packets and data collections in your Manufacturing Execution System (MES) to guarantee every order is built to spec. By utilizing clear work instructions with automatic Quality checks your Operators will have everything they need at their fingertips.

Modern MES platforms also generate permanent as-built records (eDHR) to ensure you have a complete history of every material, tool and process used on an order. With the asset traceability and revision control tools (included in your MES) your data will be reliably stored for easy access when requested by auditors.

2. Know Your Weaknesses

This isn’t your first rodeo. Audit preparation 101 is addressing and reporting on the results of your previous review. You need to show that, not only have past issues been addressed, but that the processes set in place to prevent their reoccurrence have been enforced and well documented. Being docked for a new infraction is bad, but being docked for reoccurring infractions is much worse.

Remember, no two audits/auditors are the same. To assure yourself that processes are being followed, visit the areas most likely to commit an error. This could be anywhere from a highly complex workstation to an area with an above average number of new hires. Regardless, visit your areas where failure is at his highest probability and don’t leave until you’re confident in their success.

3. Stop Cutting Corners

The truth is most manufacturers will only do the bare minimum to pass their audits. Management has other priorities and often sees these check-ins as intrusive and unnecessary. This leads to a culture of sweeping the dirt under the rug twice a year without making any real changes to support the growth of the business.

However, this line of thinking is dangerously flawed. The reality is that there are few greater risks to a manufacturer’s success than losing their certifications. How many customers would your company lose if its ISO 9001, AS 9100 or FDA certifications were revoked?

Implement a long-term solution designed to grow with your business. Do your research and select a vendor with the experience and dedication you need to succeed. Enforce quality, control production and track every order from engineering through delivery with an MES designed for your industry. 


 

Next Steps

If your company needs a plan leading into your next audit, connect with a CIMx Application Expert today to learn more about complete MES functionality. Our experienced team understands your industry and can provide the insight you need to succeed. Learn more about what the right Manufacturing Execution System can do for your shop today!

The Quantum® MES/MOM delivers the order traceability, audit control and production efficiency your shop needs to compete in a global market. Complete orders ahead of schedule and under budget with the manufacturing system designed for your industry. Build it right with Quantum.


Manufacturing Software Experience | CIMx Software

For more than 20 years, CIMx has developed complete solutions for manufacturers. The experience and innovation behind CIMx systems have delivered decades of increased production and cost savings. Quantum® is designed to deliver the production control your team needs to build it right™, ahead of schedule and under budget.

Schedule your live Quantum demo with a CIMx Application Expert today!

3 Manufacturing Slow Downs That are Impacting Your Bottom Line

Ed Deaton | CIMx Software

3 Manufacturing Slow Downs that are Impacting Your Bottom Line

Production and profit had plateaued at a Midwest Composites manufacturer. Orders were consistent enough to turn a small profit, but margins were paper-thin and the workforce was aging out of their roles.

With an influx of inexperienced new hires joining the company, the Production Manager (PM) had the idea of using a stopwatch to measure employee efficiency in the hopes of finding areas of opportunity. What this PM quickly realized was that it wasn’t his team that needed redirection; it was his processes.

These are the 3 process changes that increased production and profitability across his shop:


1. The Chain of Approval

The first issue is well known to manufacturers of every industry: a simple supervisor sign off.

When a non-conformance required a Supervisor to sign off before the Operator could continue, the PM started his stopwatch. Sign offs are commonplace and, in most cases, a non-issue. However, in this instance, the only Supervisor with authority was on the opposite end of the shop floor.

After tracking the amount of time required to simply locate, wait and walk back to the work center with the Supervisor, a shocking realization came to the PM. In the time wasted locating approval, this Operator could have completed an addition 3 pieces of work. When taking a moment to consider how frequently these occurrences take place, the amount of waste impacting the bottom line quickly added up.

2. Change Management Control

The second major slow down occurred when an experienced operator caught an error in a plan’s work instructions. These instructions had been used by less experienced workers to complete dozens of parts over the past week.

Not only did work on that line need to be shut down until a fix could be planned and approved, but the parts that had already been completed were difficult to differentiate due to limited traceability.

This shift in the schedule caused bottlenecks at fixed-time ovens slowing down production even more. There was no quick fix and once again, the clock continued to tick cutting into profit and pushing delivery dates.

3. The Problem with Paper

Lastly, after seeing the negative impact of everyday processes on profitable time, the Production Manager returned to his desk. He pulled records of previous quarters in an effort to verify if what he had seen on the floor could be as common as he feared.

After spilling over binders of paper reports, searching through spreadsheets and digging through a homegrown Access database, the third problem became clear. Not only was the data in front of him unreliable, but the amount of time required to find the information he needed was as wasteful as wandering the shop floor for a sign off.



One Complete Solution

It was only after recognizing the root causes of waste that this manufacturer could explore potential solutions. After connecting with his manufacturing network and discussing potential solutions with multiple software vendors, he determined his shop needed a Manufacturing Execution System to get production under control.

Real-time production visibility, order traceability and complete process control were required to eliminate non-value-added time and increase production. The proper Supervisors could be alerted at the click of a button and management could update change orders across the entire shop in an instant eliminating walk-around time and increasing efficiency on every part.

The data collected from each build ensured Quality standards were met on every order and gave the management team the high level data they required to keep production on schedule.

The Quantum® MES/MOM delivers the order traceability, audit control and production efficiency your shop needs to compete in a global market. Complete orders ahead of schedule and under budget with the manufacturing system designed for your industry. Build it right with Quantum.


Manufacturing Software Experience | CIMx Software

For more than 20 years, CIMx has developed complete solutions for manufacturers. The experience and innovation behind CIMx systems have delivered decades of increased production and cost savings. Quantum® is designed to deliver the production control your team needs to build it right™, ahead of schedule and under budget.

Schedule your live Quantum demo with a CIMx Application Expert today!