Category Archives: shop traveler

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!

Are Your Paper-based Travelers Holding Back Your Shop Floor?

Inefficient, annoying, error-prone and wasteful, many times paper-based work travelers are the source of countless shop floor problems and might be holding production back.

 By David Oeters, Corporate Communications with CIMx Software

Many times, discussions about paperless manufacturing and MES focus on hard data (35% increase in production and a 45% decrease in quality defects – hurray!), the ROI or the global enterprise (real-time shop floor visibility and control, and sustainable process improvement and enforcement – alright!).  We forget to notice the little improvements that have the greatest impact on the shop floor – the things that make everyone’s life easier.  They bring joy, increased job satisfaction and improve the shop floor quality-of-life.  It may not directly impact the ROI, but it sure makes everyone happy.

Exhibit A: The Paperless Shop Traveler
What steps can you take to improve performance (and happiness) on your shop floor?  Illustration by www.colourbox.com

What steps can you take to improve performance (and happiness) on your shop floor? Illustration by http://www.colourbox.com

Face it, shop travelers that are a huge bundle of paper, checklists, drawings and data collections can be a major pain.  Those annoying bundles of work instructions and shop floor records that are painstakingly printed every morning, then laboriously assembled and bundled into plastic sleeves, bags, or bound together by pins, clips or whatever is on hand.  It makes its journey across the shop, carried by hand or thrown on a cart.  As changes happen, notes are added, papers removed and measurements made.  It’s dropped, spilled on, and crammed into corners.  Pieces are lost and critical information gets shuffled back and forth with everyone hoping nothing gets missed.  Let’s be honest, all that paper isn’t necessary!

When it’s all done, the records are stored away – those piles and piles (and piles) of records.  Maybe someone has to collect the data scrawled on the traveler, then (re)input the information.  Finally, it’s all shoved into a box and carted away to storage.  If you’re lucky, maybe you have a process that converts it to a pdf.  Maybe.

That’s what happens all too often.  Like I said… it’s annoying, inefficient and error prone.  The paper-based traveler is the source of headaches and frustration for many shop floors.

It doesn’t have to be that way.  An integral feature of paperless manufacturing is removing the unnecessary paper from the work traveler and leaving you with a format that makes sense for your shop process.

With Quantum or Interax and CIMx Software, each work order created is a separate file in the system.  Important details are part of the file, and easily accessible.  Work and set-up instructions, safety material, important training information and more are all attached to each work order, and can be accessed when and wherever necessary.  Most importantly, only the latest approved information can be accessed, and when needed change orders can be signaled through the system and made in just a few moments.  After all, there’s proof visual work instructions are far superior to paper-based ones.

From the shop floor, quality checks can be made and added directly to the work order, where it can be securely stored.  If there is a file or digital photo the shop floor wants to add to the file, it can be added with a press of a button.

From anywhere you have access to your network; you can track the progress of the paperless traveler with real-time information.  No more running to the shop floor asking questions, or flipping through pages to swap out flawed work instructions, or retroactive quality checks.  Sounds good, doesn’t it?

When the work order is complete, it is securely stored in a digital archive.  You can access the file at any time, and a complete as-built record is a single button press away.  Forget the stress of audits, everything that needs to be done is done automatically.  Want to run reports on the data to help optimize production?  No problem.

Eliminating unnecessary paper from your work travelers may not be your primary reason for implementing a paperless manufacturing system, but it may be what your shop floor is most thankful for when the project is complete.  Shop floors are quickly moving paperless, so now is the time to get a head start on the process and a leg up on the competition.