The 9 Most Common Manufacturing Symptoms, and How to Cure Them

The 9 Most Common Manufacturing Symptoms, and How to Cure Them
When looking for a solution to manufacturing problems, it’s important that you find the cure rather than just treating the symptoms.


Common Manufacturing Symptoms

Every manufacturer faces daily frustrations. Problems crop up that slow production, increase paperwork and waste resources. It isn’t until these issues start impacting the bottom line that solving the problem becomes a priority. Unfortunately, by that time, the damage has been done.

Think of your day-to-day production issues as symptoms and your manufacturing software as the doctor. You may schedule a check-up for a minor pain, but you expect your doctor to address the underlying issues. If your doctor only focuses on curing the symptoms, you’ll be back in their office with a similar problem the next week.

Manufacturers share a lot of their symptoms with our team when discussing potential production solutions. Here are some of the most common.

The Most Common Manufacturing Symptoms:

  • Decreases in Quality
  • Increases in customer turnbacks
  • Generating too much scrap
  • Missing ships dates
  • Increases in overtime
  • Frequently failing audits
  • Unreliable production records
  • Misplacing orders
  • Losing customers

You can put a band-aid on any of these problems by installing sidecar modular systems, but inevitably, that symptom will find a way to manifest in another area of your shop. Modular systems rely on this “finger in the dam” approach to keep you coming back for more. Your shop doesn’t need another short-term solution. It needs the cure.


The Cure is Production Control

In every manufacturing symptom listed above, the underlying issue connects back to a single problem: a lack of end-to-end production control.

The right MES enforces Quality and provides your supervisors real-time visibility on every order. Process control equates to less operator errors, which increases Quality and eliminates customer turnbacks.

Higher Quality eliminates scrap, cuts wasted resources, keeps production on schedule and brings your project in under budget. If you’re ahead of schedule you aren’t paying for overtime or rushed shipping costs. Your business is charging the same amount with less overhead while building trust with your customers.

In addition to end-to-end production control, a true MES collects data on every order in a permanent as-built record. This eliminates the tremendous amount of time and manual data entry errors that plague production. With production under control and your order data all automatically logged in a single, complete as-built record, audits are a breeze.


Next Steps

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. Cure your shop floor problems, with Quantum.

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

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Production Control from Coast to Coast

Quantum connects and controls production for US manufacturers.

Contracting more orders than you have the resources to complete seems like a great problem to have to most manufacturers. However, it’s the consequences of success that have forced many unprepared manufacturers to close shop. Overtime hours chip away at profit margins, over-worked employees become more likely to commit errors and late delivery frustrates longtime customers.

The irony is that the same processes that elevate a company to success can ultimately become that company’s downfall. To succeed in manufacturing, your shop must automate data-capture, enforce build conformance and direct production with real-time WIP dashboards. Keep your delivery promises to every customer and continue your business on the path to success with a production control system designed for every stage of manufacturing.

One CIMx customer was growing at a rapid rate. Business had taken such a positive turn that the company needed to expand operations to the West Coast. To guarantee the level of Quality was consistent at their new facility the company selected Quantum to connect and control production from coast-to-coast.


Case Study: Production Control from Coast to Coast

The Problem
An East Coast electronics manufacturer was growing. Overtime hours skyrocketed and rushed shipping costs began impacting their already narrow margins. This increase in work was welcomed, but resources were thin. To accommodate the increased demand, a secondary shop was scheduled to open on the West coast.

“We were getting by,” explained one production supervisor, “but there were problems we didn’t have solutions for… no records and no good way to track work. We had people just standing around the shop because they were missing information or materials.”

The Solution
Quantum was implemented at both facilities to connect and control the entire enterprise under one sustainable platform. By utilizing Quantum’s advanced planning center and end-to-end production controls, the manufacturer was able to enforce best practices on every build, increase quality standards and track operator/order data from both locations.

In a matter of months, both shops were on schedule and operating at a level of quality and efficiency never before thought possible. By utilizing digital work packets, automatic tolerance checks and real-time WIP quality alerts, the manufacturer was able to prevent common operator errors, stay on schedule and enforce engineering changes from 3,000 miles away.

This customer has continued to grow and is once again expanding their facilities. Record, report and react to errors on your shop floor before they become bottlenecks. Support compliance certification and become the supplier your customers go to first when a job has to be completed on schedule. Build it right™, with Quantum.


If you’re interested in shop floor control, ahead-of-schedule production and complete order visibility, connect with CIMx Application Expert Liz Hamedi at 513-248-7700 x416, or email the CIMx team directly at info@CIMx.com.

CIMx Software celebrates 22 years of US manufacturing software innovation!

After two decades of advanced planning and production control, CIMx announces Quantum 6.0 release for spring of 2018

They say you can learn a lot about a company by understanding where they got their start.

CIMx began its journey in 1996 by developing Process Planning and Engineering systems for Fortune 500 US manufacturers. That foundation in advanced planning, highly regulated compliance reporting and agile engineering change management has fueled more than 20 years of manufacturing software innovation.

“From day one, the goal was to develop our systems in a way that even the shops just starting out could have access to the same tools leveraged by our Fortune 500 customers…” said veteran of the manufacturing tech industry and CEO, Anthony Cuilwik, PhD. “Our Quantum platform achieved that goal. It really is the next generation of manufacturing.”

From aerospace and government defense contractors to medical device, carbon composites and beyond, CIMx has delivered the same care for detail and process demanded by their customers for more than 20 years.

“US manufacturing is going through a renaissance. Shops are growing and their old manual processes just can’t keep up with customer demand.” explained Director of Messaging, Ed Deaton, “Quantum delivers the tools both engineers and operators need to drive velocity, eliminate scrap and ship ahead of schedule, all from one sustainable platform.”

CIMx’s mission of delivering production control to manufacturers of all sizes, regardless of revenue stream, is alive in Quantum. The latest system release is scheduled to deploy spring 2018 as a free upgrade to all licensed users.

If you’re interested in shop floor control, ahead-of-schedule production and complete order visibility, connect with CIMx Application Expert Liz Hamedi at 513-248-7700 x416, or email the CIMx team directly at info@CIMx.com.

 

 

 

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!

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.

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.