Category Archives: MRP

5 More Easy Shop Floor Quality Improvements

Production Control Systems and Quality Improvement

We are all in the quality business. Wasted time, scrapped materials and customer turnbacks reduce margins and damage our reputations. It’s only by putting the proper systems in place that our shops can achieve maximum efficiency and profitability.

With your existing production control system (PCS) and these five easy steps, your business can eliminate scrap and accelerate production in a matter of weeks.

  1. Review Non-Conformance Issues Daily
    Evaluate your previous day’s non-conformances in your morning production meeting. One competitive advantage your PCS provides is access to real-time production data. Don’t let your team revert back to weekly updates. Keep your processes as agile as your operators. You have all the data you need at your fingertips; use it.
  2. Monitor Quality Throughout Live Production
    Leverage buy-offs and tolerance checks at critical points throughout production. Stop non-conformances in their tracks with your Production Control System’s quality gates. If a check fails or a measurement is marked out of tolerance, use your PCS’s real-time alerts to notify the right team member to resolve the issue and keep production running. If you expect to increase both production velocity and quality rates, it’s essential that you monitor quality throughout production, not just at the end of the line.
  3. Properly Schedule Machine Maintenance and Tool Calibration
    Update and expand your machine maintenance program with digital control. Schedule more frequent maintenance to limit disruption or implement your PCS’s asset management capacity to track usage rates. Why risk falling out of compliance on a run when you have all of the tools you need in one system? Guarantee your customers that every operator, asset and machine is certified for its role in production.
  4. Create Standard Workaround and Rework Paths
    Plan standard workaround and rework paths to maintain production velocity when problems occur. Your ERP is an essential tool for running your business, but your Production Control System shines when production doesn’t go as planned. Take advantage of your PCS’s ability to map proactive solutions to problems from the common to the critical and resolve production issues before they have the chance to disrupt ship dates.
  5. Review Reports and Trend Analysis to Identify and Resolve Errors
    This is why you invested in a Production Control System in the first place. Successful shops require the visibility to track and control production with the agility to handle even the most complex of processes. Use reports and trend analysis to identify the source of common errors, and then utilize process control to eliminate errors in the future. Take control of your shop, eliminate scrap and deliver your customers the highest quality product available.

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Efficient Manufacturing

How one midwest manufacturer increased production by 35% while reducing scrap by 80%

Case Study: Scrap Down. Production Up.

A midwest make-to-order manufacturer was experiencing both escalating levels of scrap and a consistently under-performing shop. After experimenting with a series of homegrown solutions, a production supervisor connected with CIMx to deliver a comprehensive, sustainable solution.

“Now we can zero-in on problems very easily… as long as I’ve been in my position, I’ve never been able to dig into my business like this. It’s been great!”
– Assistant Production Supervisor

The previous processes had utilized a homegrown Access database to track parts, tools and materials and paper sign-offs to document quality. When the team member responsible for managing the database retired, a more sustainable, efficient and reliable approach was required that would both accurately track the manufacturing data on every order and control the production process from engineering through delivery.

The Power of Production Control

CIMx Software’s Quantum production control system was selected to both migrate data out of the legacy systems and the provide shop floor visibility and quality control for every order. CIMx worked closely with the production team to understand their production processes and map out the solution that met their needs. Once configured, the Quantum solution was not only familiar to the operators but offered extensive hard and soft cost savings for the company.

35% Increase in Production. 80% Reduction in Scrap.
– Data from 2018 CIMx System Engagement Review –

In the first 6 months, this shop has already reported dramatic savings and increased revenue generation from the implementation of Quantum. By enforcing quality checks, utilizing digital planning and delivering interactive work instructions to their operators, production has increased by an average of more than 35% per day. As production rates increase, there has been a simultaneous 80% reduction in scrap!

See what Quantum can do for your shop!
Explore the Power of the Quantum Production Control System!

Imagine reporting these numbers to your CEO. What could you do with all that additional revenue returned to your budget: upgrade facilities, hire more operators, increase outreach? Whether your shop has outgrown past production processes or your facility is being pushed to deliver more with less, Quantum is your solution.

Learn more about the timeline and impact of introducing a production control system to your shop by connecting with a CIMx process expert today!

Ready to track, control and increase production velocity?
Connect with an Application Specialist today!

The Problem with Managing Tools, Parts, and Materials in your ERP – and What You Can Do About It

Not long ago, we worked with a manufacturer struggling with a serious scrap problem.

They were a make-to-order composite manufacturer building an expensive product with several critical components. The problem was – operators often used the wrong component. Components were similar and the specifics precise, so every mistake generated scrap, delayed the shipment, and left the sales team scrambling for new excuses.

It didn’t take long for the CIMx Application Specialist to discover the problem… the shop floor was trying to manage production with a bill of material in their ERP.

The ERP Doesn’t Understand Your Bill of Materials

The bill of materials is a critical part of the production process, but if it’s being managed in an enterprise system like an ERP, the system and the shop floor sees it more like a shopping list than a specification, and that’s a problem costing your business productivity and profit.

For manufacturing, especially discrete manufacturing, assets are more than just a list – they are critical specifications required in accurate and error-free manufacturing. But if a shopping list is all the shop floor gets from the ERP, you have lost production conformance. There’s no validation or control in how parts and materials are used in production – just a list that may or may not be referenced later in the production process.

The Struggle Is Real on the Shop Floor

We’ve seen it happen before – operators find costly workarounds for the gaps and problems the ERP is causing. For example:

  • The shop floor hides tools they know they will need because the ERP isn’t tracking production or the assets used. It’s better for them to hide tools now than search for them later.
  • Operators grab materials during kitting without even consulting the bill of materials. They’ve done it before and know what they’re doing.
  • Tools and machines on the shop floor are out of calibration because the static bill of materials doesn’t track the shop floor or assets.
  • Experienced operators work from memory anyway, and never even look at the plans or bill of materials because there’s no validation, no process conformance, and no control of work.
  • There’s no way to specify tools and materials anyway, so mistakes aren’t caught till the end, and then it’s a problem for somebody else.

Many shop floors operate like this. Work is done and products ship, but it’s often in spite of production processes and planning. The ERP can’t support the conformance and control required for make-to-order manufacturing.

Process Control for Make-to-Order Manufacturing

The problem is the reliance on their ERP. The ERP can store information, but it’s not driving the conformance and control this manufacturer needs. The hands-off manufacturing approach of the system is fertile ground for mistakes and increased production costs. The shop floor tries to eliminate the errors, but they’re getting no support from the ERP.

The first step to solving the scrap problem for this customer is moving the bill of materials out of the ERP during production and into a production control system – Quantum.

During kitting, Quantum validates critical materials against the specifications on the bill of material. If the shop floor picks or tries to use the wrong materials, a simple barcode scan will flag the mistake and corrective action can be taken immediately. The problem ends there, minimizing the cost and impact on the schedule.

If necessary, conformance can be driven throughout the production process using pass/fail data collection and automated validation checks against the parts and materials specifications on the bill of material. The manufacturer can control the process and add necessary safeguards.

Problems are eliminated. The shop floor gets the support they need at every phase of production. The bill of material becomes a tool for error-free manufacturing and the foundation of conformance rather than a shopping list.

Contact CIMx today to learn more about Quantum and how you can turn a bill of material into a production tool that drives profit, and eliminates errors and scrap.