Category Archives: Manufacturing Work Flow

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!

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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!

Do You Know Where Your Production Assets Are?

While production requires tools, materials, parts and equipment, many manufacturers don’t track or properly manage these assets. This oversight adds “hidden” production costs like scrap, inefficiency and waste – costs that can quickly overwhelm profit.

How much scrap and waste is generated by one of your operators using the wrong part or searching for a missing tool? How many of your late shipments are symptoms of orders sitting on the shop floor waiting for missing parts or materials? Problems like these are common when companies aren’t tracking and controlling assets in production.

Without granular data to optimize and control asset usage, mistakes are made and costs increase. The Quantum production control system manages parts, materials and tools during production, eliminating these mistakes and reducing costs.

Empower Production with Asset Control

A production control system actively links the management of tools, parts and materials to manufacturing activities.

Serialized assets, or assets given a unique identifier, are not only be used to track parts and materials for regulatory compliance, but also eliminate the scrap and waste caused when the wrong parts and tools are used. Engineering specifies a tool to be used in an operation, the operator then validates the correct tool with a simple bar scan before work begins. The validation adds invaluable conformance and control to the shop floor.

By collecting and analyzing production data on tool usage, you can track when an asset requires calibration, further reducing mistakes and scrap. If a tool is due for calibration, an alert is sent and the tool is put on hold until the proper calibration can be performed.

Data from the production control system can further improve asset efficiency. Over time, as you begin collecting production data and matching it to the serialized assets used, tools that aren’t operating efficiently are identified. Corrective action, such as more frequent calibration or part replacement, can be taken before the issue becomes a serious problem.

By managing tools, parts and materials in a production control system and validating on-hand quantities, you eliminate a root cause of late shipments.

Before an order is released, Quantum validates parts and materials are available. The system automatically lists where they are stored, reducing the time and effort necessary for kitting. If materials or parts are missing, the floor supervisor can put a hold on the order until the assets are available. Inventory can be moved to fill the order, ensuring the shop floor stays focused on critical and available work. You can identify an asset issue at the earliest stages, allowing corrective steps to be taken. Linking asset availability eliminates wasted time and helps ensure orders ship on-time, every time.

Lower the Cost of Production

Assets are a critical component of a successful and efficient production process. Production costs and shop floor errors increase when there isn’t a link between production and asset management, especially for make-to-order manufacturers that work under strict conformance and control requirements.

Once the link is in place and the production team is synchronizing work and asset usage, you’ll start identifying and correcting additional sources of errors and inefficiencies, further fueling production cost savings.

Contact CIMx today to learn more about part and material management in Quantum, and discover how production control software can lower costs and increase productivity for your business.

Insider Secrets to System Integration for MES and Paperless Manufacturing

There’s confusion out there in the MES and paperless manufacturing market about what “system integration” means and what it can do for your company.  We cut through the confusion and offer tips for ensuring integration leads to benefits for you and your shop floor.

By David Oeters, Corporate Communications with CIMx Software

How can you navigate the myths and legends of manufacturing system integration? Illustration by www.colourbox.com

How can you navigate the myths and legends of manufacturing system integration? Illustration by http://www.colourbox.com

System integration.

For many manufacturers, the term has taken on mythical, magical, properties.  Like some IT or software unicorn, many companies are questing for the holy grail of total “SYSTEM INTEGRATION.”  They call it the “digital enterprise,” “enterprise integration,” or “operation integration.”  Companies feed into the myth, believing they cannot achieve operational Nirvana without system integration.  Current IT trends and tools lend support to these beliefs, especially big data and advanced analytics – both require integrated systems.

There are benefits to system integration for savvy manufacturers.  It’s worth the investment, but many companies fail to fully realize the benefits in their single-minded focus on complete system integration.  They may even be hurting production.  The goal shouldn’t be a monolithic digital enterprise, but improved productivity and better business processes.

We want to take a brief look at system integration, focusing on the benefits and dangers rather than the technology (which can change quickly as new products and techniques are released), and offer tips on how you can design a more successful integration project.

What is system integration?

System integration is a computer technique where individual software components are combined into an integrated whole.  With interconnected systems, electronic data is shared and exchanged across the network, ensuring accurate information is available anywhere and at any time.  Integration improves communication and coordination.  By linking computer systems or software applications together, either physically or functionally, the entire computer network acts as a coordinated whole, eliminating information “silos” that occur when data is input in different locations.

There are several methods of system integration.  Most utilize a variety of techniques, not just new software or hardware.  Cultural adaptation and coordination, as well as an evaluation of business processes, are also required for a successful integration.

The Benefits of system integration

Follow our tips to ensure maximum benefit for your next system integration project.  Image by www.colourbox.com

Follow our tips to ensure maximum benefit for your next system integration project. Image by http://www.colourbox.com

The primary benefit of integrated systems is improved functionality.  Data within the organization will be fully harmonized, creating a more capable system, improving performance and enhancing existing systems.  Reports will access more data, improving accuracy and decision-making while delivering better operational management.

Manufacturing pioneered the early study and use of system integration as companies sought improved operations through the use of Computer Integrated Manufacturing (CIM).  In CIM, companies used computers to integrate manufacturing activities.  By integrating computer systems, such as product development, process planning, production, and delivery and after sales, companies could deliver accurate information where and when it was needed, and in the format that was required.

Companies that smartly invested in CIM were rewarded.  The US National Research Council asserts production can be improved through CIM by as much as 40 to 70 percent.  Design costs can be reduced by 15 to 30 percent, and overall lead time can be reduced by 20 to 60 percent.

Navigating the dangers of system integration

Simply pushing computer systems together, or imposing a new workflow process or computer application, is not enough to achieve beneficial system integration.  Many times, the drive (or quest) for system integration begins in the front office, not the shop floor, which can lead to a number of problems for production.  A system that benefits one department may not benefit or even work for another, hindering productivity, reducing benefit, and building resistance to the overall integration plan.

The fact is, the business processes and computer systems that work for finance, IT, or product design aren’t an optimal solution for production.  An ERP is a transaction-based system, and the data, output and processes are different than a behavior- or process-based MES or paperless manufacturing system. A transaction-based system catalogs data, while a process-based system manages workflow with information.  Trying to impose a transaction-based system on shop floor workflow is inefficient.  Any advantage gained from the system integration is lost as more resources are required to complete work.

In an effort to create a common data format or a shared operational system for the integration, many companies will sacrifice operational efficiency.  Manufacturers will lose the operational functionality they need.  A transaction-based system will never offer the tools necessary to optimally manage redline edits or deliver process enforcement, even if it works great for HR or design.

Consider the cultural side of the equation.  Can you imagine imposing engineering workflow or finance workflow on an assembly or production line?  It sounds silly, but many companies do that when the purchase a “suite” of pre-integrated software systems.  It delivers front office benefits by sacrificing operational efficiency.

Tips for successful software integration

Don't forget to consider cultural needs, as well as technological needs, when planning an integration project.  Illustration by www.colourbox.com

Don’t forget to consider cultural needs, as well as technological needs, when planning an integration project. Illustration by http://www.colourbox.com

Consider these tips as you evaluate the opportunities for system integration:

  • Set specific goals for the integration, and ensure those goals are met with a clear ROI. Many times, companies will continue to add functionality as their costs and project complexity grows exponentially.  Add in the costs a piece of functionality may have to one area, and for some projects an ROI will never be achieved.  Manage your initial expectations to focus on the initial key project drivers.
  • Look at not only a technical solution, but a cultural one as well. Start the process by breaking down the cultural boundaries in your company before rolling out a technical solution.  This will require buy-in and consensus.  Make clear not only the goals, but the expectations.  Give each area a voice in the final solution, and ensure their needs are met.
  • Look at delivering the project in phases, rather than a single, massive installation. Any enterprise-wide system integration is more than just software installation, it requires a cultural shift.  Tackling an enterprise project is not just technically difficult, but culturally difficult as well.  A phased implementation will eliminate many of these problems.
  • Look for added value in the project, and ensure it is real value, and not just functionality. For example, linking design and production on a single system is one tactic, but many times system integration can be as simple as sharing a single database with revision control and an approval process, and doesn’t require an entirely new software package.  The value of the project is achieved without the additional and unnecessary complexity.
  • Beware of vendors promising an “integrated” solution. Many companies are working to build “digital enterprise” software.  Their tactic  is to “purchase” solutions to be integrated into their own system.  The result of these purchases is often problematic.  The integration the vendor makes by smashing the system together may not match your current processes or needs, and will add complexity to the installation at your site.  The benefit the vendor gains by marketing an “integrated” solution does not translate to your shop floor or enterprise.
  • System integration doesn’t require a single “master” system to manage operations. Look at sharing data across relevant systems using an application-independent data format.  This project can easily be done in phases.  For example, send orders from your ERP to your MES, automatically generating orders for production.  Once a product ships, send the product data to the PLM to create a master record.  Strategically link your systems to maximize value and increase functionality, rather than making wholesale changes to your operation or workflow that lead to enterprise disruption and the never-ending project “roll-out” that is outdated by the time it finally launches.

 

Just like a magic unicorn, more often than not a single “enterprise” system sounds good, but the implementation is problematic.  Forcing change and new processes to ensure a single system isn’t integration.  It leads to unnecessary complexity, project delays, and problems.  When planning a project, consider the needs of each area, and how the system will benefit them.  Conduct the project in phases, with clear goals and expectations.  Want to learn more, or see how you can begin a phased implementation of a system integration project?  Give us a call or leave a message.

One Simple Step that Improves Manufacturing Productivity

Your shop floor hides dangers that eliminate more than 13 hours of productivity each week for every employee.  Learn how you can quickly improve productivity and profit with one simple step.

By Kristin McLane, President of CIMx Software

As a culture, we are driven by technology.  There’s a chip in your coffee maker and a computer in your car, not to mention a smart phone that connects you to the greatest database in human history.  Technology can make our lives better and improve productivity.  With technology, it’s possible to get through your whole day without thinking (a skill many seem to have mastered already). But, some technology can be disruptive.  Rather than helping us work better, it hinders productivity.  Consider email – email can be a constant interruption, wreaking havoc on your day if you’re not careful.

The Dangers of Technology

Are you letting distractions hinder your shop floor productivity? Image by www.colourbox.com

Are you letting distractions hinder your shop floor productivity? Image by http://www.colourbox.com

Many of us start the day with a list of priorities.  A good day would see every item on the list complete.    Unfortunately plans for productivity are often waylaid by the disruptive influence of email.  Each morning, you grab a cup of coffee (or your vice of choice) and sit down at your computer.  Then email starts beeping at you, demanding attention.  Email is like a thief, stealing your time for unplanned distractions.  Sure, some messages may be important, but most aren’t.  They certainly aren’t more critical than the items on your list.

In 2012, the Huffington Post reported that the average worker spends 25% of their day reading, attending to and answering email.  Just one short year later, that number jumped to 28%.  That’s roughly 13 hours a week.  What could you do with an extra 13 hours of productivity each week?  What could your shop floor workers do with that extra productivity?

Many manufacturers embed distractions in their workflow just as distracting, if not more, than email.  We plan for distraction in the workflow by having workers seek out information in massive binders or consult safety manuals, then wonder how we can improve productivity.

The Effect of Interruptions

Interruptions have ripple effects far greater than the interruption itself.  There’s an entire field devoted to Interruption Science, the study of what happens to job performance after an interruption.  Studies show that interruptions significantly disrupt workflow.  Employees need time to recover, leading to even more lost productivity.

The New York Times reports that 40% of workers cannot complete the task the same way after an interruption.  In fact, another study found an interruption during work increased errors by as much as 20%.  Companies know eliminating distractions and interruptions will drastically increase productivity and work quality.  For example, Toyota (with andon cords) and other companies have made it a priority to remove any interruption or distraction from the shop floor.  The goal is simple – protect the worker, improve production and profit.

 Increase Productivity with Paperless Manufacturing

Properly implemented, an MES will manage information and keep your shop floor focused on production by automating many of the tasks that were once “interruptions” in paper-based production.

Improve productivity and profit by removing a major source of shop floor distraction - paper. Illustration by www.colourbox.com

Improve productivity and profit by removing a major source of shop floor distraction – paper. Illustration by http://www.colourbox.com

Missing parts, unclear instructions, lack of certification and other critical issues cause distraction and interruptions to the shop floor workforce.  These interruptions, common in a paper-based work environment, quickly add up to 13+ hours of lost productivity each week.  If you look at any paper-heavy shop floor, workers are often doing one of two things – checking their work in a paper traveler packet, or ignoring the work instructions and doing work as they have always done.  Either way, you’ll pay for the interruptions with lost productivity or errors.

When a worker undertakes a task requiring precision, electronic instructions reduce confusion and provide everything the shop floor needs to complete the work without interruption.  Engineering specifications, safety instructions, machine set-up and more are only a mouse click away if they need it.  With all the information they need at hand, workers are more confident as they complete tasks, while the system provides a seamless transition from one task to the next, greatly increasing the overall performance of the shop floor.  Your team can focus on production.

Studies show distractions and interruptions lower overall worker productivity.  The goal of any shop floor manager should be to remove distraction and provide workers with everything they need to complete work better, faster and with fewer errors.  Paperless manufacturing manages workflow, automating many tasks, with productivity gain exponentially enhanced with distractions removed.

Consider this – how quickly could you deliver an ROI on a computer system that gave each worker 13 more hours of productivity each week?

Want to learn more, or see how our system can support workflow on your shop floor?  Give us a call or leave a message for a no-cost consultation on paperless manufacturing.  We’re happy to help and answer questions.

Pushing the Envelope with MES and Paperless Manufacturing

Want to get the most out of your paperless manufacturing system? Evaluate the push technology in your system using a few simple tips.

By David Oeters, Corporate Communications with CIMx Software

In manufacturing, a few seconds can mean the difference between success and scrap.  A single error can snowball and lead to missed shipping deadlines, lost profit and angry customers.  Consistency and repeatable processes is the key to success, while complexity leads to errors, waste and worse.

Push technology systems, which automatically deliver contextually relevant data to the shop floor user, have significant benefits for manufacturers.  Despite this, many companies still rely on less efficient pull technology systems for their MES and paperless manufacturing.  Pull systems require the user request the data each time, adding complexity and introducing opportunities for errors.

Pull Technology

Pull technology requires a specific user request for the release of data.  Typing the URL or clicking the link of a web page is an example of pull technology at work.  The user requests information using specific input and the information is delivered.  Logging in to a work station terminal, following system-based procedures, sorting through the work of the day, and then requesting the work instructions is an example of pull technology.

Pull technology can be error prone and requires effort and time from the user.  With some complex or overly engineered MES, this can be significant time, unnecessary effort, and any errors in the input can be costly.  Users request the wrong work instructions, or unapproved plans are released.  Template-based systems utilize pull technology.  Users input data in specific fields, and the system dictates the work process.  This introduces unnecessary complexity and additional training.  The effort needed to log in and find the work instructions is non-value added time.  With many systems, unnecessary steps are added simply to suit the system or accommodate system-based processes.  There is a tradeoff between making the solution easier to program and making it more efficient for the manufacturer using the software.

Push Technology

What can push technology do for your shop floor production? Illustration by www.colourbox.com

What can push technology do for your shop floor production? Illustration by http://www.colourbox.com

With push technology, data is automatically delivered to the user, either on a set schedule or when a specific circumstance or trigger is met.  An automatic calendar update is an example of push technology.   With automated information transmission, errors are eliminated.  The correct information reaches the right people at the right time in the process, every time.  Complexity is reduced, since non value-added procedures are removed.  With the right operation being sent at the correct time, you have better control over the process.

An example of push technology on the shop floor could include an RFID badge, barcode or fingerprint scanner keying a user to a work station.   With a swipe of the barcode or the RFID, the system is aware of the user at the station, and the prepared work is pushed to them.  Before the day begins, new orders have been pulled from the ERP or MRP systems, the work instructions assembled and routed.   Staff prepares the kitting and delivers parts, tools and materials to the work station.  The worker arrives can begin work moments after they arrive.

As the process becomes more automated, using procedural enforcement, repeatable processes, automated data collection, and automatic validation of tolerances, the shop floor can now focus on value-added tasks such as eliminating errors and improving production.  The administrative tasks such as verification of processes and data collected, while necessary, add less value and can be automated.  Push technology automates the administrative work to optimize production processes and profits.

Delivering on the Promise of Push Technology

There are shop floor solutions, MES and paperless manufacturing systems, on the market designed to deliver the benefits of push technology when appropriate.  As you evaluate potential solutions, ask a few key questions of the system:

  • Does the system use a newer platform technology? Web-based solutions enable the adaptable systems found with push technology.  If the system used an older platform requiring additional work to integrate or additional steps to simply start, then it won’t deliver the benefits found in push technology.
  • Will it match and benefit your existing workflow processes? Can you reuse your existing work plans and best practices?  If the system is forcing an entirely new process on your shop floor, or requiring you to rewrite or recreate your work instructions in a new format, then you have a system based entirely around pull technology.
  • How much training is necessary? How complex are the work screens?  If training is a significant cost in the implementation, or the screen is busy with buttons and input fields, then you can be sure your team is going to need to use that training and all those buttons with pull technology, rather than focusing on shop floor production.

The goal of a paperless manufacturing system should be to synchronize the people, information, and materials on the shop floor.  Utilizing push technology in the system ensures a tighter synchronization, getting the right information to the right people at the right time with fewer errors.  It’s another way you can ensure you’re maximizing the benefit of a shop floor system.

Questions, or want to see how paperless manufacturing can improve production and remove errors on your shop floor, then give us a call.  We’re happy to help.

6 Ways Paperless Manufacturing Can Help Your Shop Floor

A paperless manufacturing system can quickly and easily deliver even more benefits than you might think.

By David Oeters, Corporate Communications with CIMx Software

Ensure an early ROI for your project by focusing on items with the greatest return. Illustration by www.colourbox.com

Ensure an early ROI for your project by focusing on items with the greatest return. Illustration by http://www.colourbox.com

Many companies begin researching paperless manufacturing to solve a single problem.  Depending on the problem, paperless manufacturing likely holds the solution.  No other shop floor investment addresses so many of the challenges manufacturing faces.  Which is why manufacturing firms spent more than $5 Billion on MES and paperless manufacturing solutions in 2013, and estimates predict the MES market will expand more than 20% annually.

But, a powerful and capable paperless manufacturing system offers more than just a single solution or capability.  With the right system, you have workflow control and complete shop floor visibility.  As you consider a system for your shop floor, take a look at the six capabilities that provide the foundation of any paperless system.

1)      Track, measure, record and dynamically manage work flow.

Every manufacturer must track and manage workflow – it’s the key to a production system.  The methods used to manage work vary between manufacturers, and can lead to vastly different results.

With paperless systems, work flow is digitized, allowing automated tracking and recording of work.  Management of the work flow is made possible with instantaneous communication and error-free work instructions.

2)      Create production plans with approved, accurate work instructions.

Operations benefit from standards, best practices, and process improvement plans such as Lean manufacturing and Six Sigma only when they are implemented in production.

Using a paperless manufacturing system, procedural enforcement ensures the productions team incorporates best practices on the shop floor.  Planners use only the most recent and approved plans.   A library of approved work plans, best practices and standards ensures your team completes planning in less time and with better work instructions.

3)      Collect data on all production operations.

Data is a valuable commodity.  Unfortunately for many manufacturers, the age and inaccuracy of collected data significantly limits its usefulness.

A successful paperless system collects real-time data at each work station.  The system automatically verifies specified quality metrics fall within acceptable ranges.  The collected data becomes a valuable tool for manufacturers.

4)      Create a complete, accurate production record for all products.

The production record includes every action taken, every specification read, every training module referred to, every log in and out on a job, and every measurement taken on a product.

Most (if not all) manufacturers monitor shop floor activity, but an effective paperless solution automatically creates a comprehensive production record used to verify all actions were completed accurately.  This unified record, compliant with all regulatory body or key customer standards, provides a rich source of accurate data for future use.

5)      Have a continuous real-time view of all open work orders.

In the past, a real-time view of production meant walking around the shop floor asking questions.

With a paperless system, manufacturers can get a comprehensive, real-time view of production.  Current work can be seen in the context of actual work flow order at each moment.  This real time view is invaluable to plant management and quality assurance, helping proactively solve problems and ensure smooth production.  It is a major component of business intelligence.

6)      Enable seamless communication across the enterprise from a single source of truth about production.

Many companies struggle with data coming from multiple locations with no coordination, and often communication focuses on building consensus rather than manufacturing.

Paperless manufacturing is built around the concept of a single source of truth about the product.  Everyone works from the same data and toward the same goal.  The solution has the flexibility to manage, record, and distribute information from multiple sources, eliminating mistakes from faulty information while managing WIP all the time.

Delivering Benefits and ROI with Paperless Manufacturing

Process Improvement graph.

No other shop floor solution addresses so many production challenges, or offers a bigger benefit. Illustration by http://www.colourbox.com

With paperless manufacturing, companies reduce quality defects, eliminate human error, minimize waste and scrap, and increase productivity.  The system delivers shop floor control and visibility like no other product on the market.

Current trends in manufacturing are pushing companies to adopt paperless solutions.  Customers demand more customization and quicker turnaround times through smaller production runs.  They expect real-time information on the status of their orders.  Paperless manufacturing offers a clear advantage over paper-driven processes in delivering these goals.

Want to learn more, or to see what paperless manufacturing can do for you, then contact CIMx today.  We’re happy to help.