Tag Archives: manufacturing

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!

What to Consider When Selecting a Manufacturing Software Vendor

Liz Hamedi | CIMx Software

In this day and age, customer service and reputable businesses are getting harder to find. There is more to the sustainability of a software system than just the promised functionality. In fact, a system is only as good as the support and the reputation of the company that maintains it. This means it is critical to find a vendor that proves they are trustworthy, knowledgeable and collaborative.

Avoid the Vendor that does it all.

If you’ve ever started down the software implementation path, you’ve likely been blindsided by costs that you hadn’t planned for.

Maybe you had to add a module or two to meet your core requirements. Maybe you needed to pay extra for support or additional training. Or maybe your vendor required you to purchase an additional service to upgrade or integrate?

Unfortunately, the list goes on and on. To combat this, look for a vendor that will not say “yes” to everything. A trustworthy vendor will ask the right questions to ensure you get what you need, without adding additional cost for little to no benefit towards solving your long term goal.

Find a Vendor that supports your buying process.

Your primary goal is to find a system that is reliable with minimum support needs. However, it is important to know that if something does go wrong, or if you have a question, you won’t need to waste time hunting down a response. Although you can never truly understand the future support structure until you become a customer, there are red flags throughout the sales process that you should look out for.

When you ask your sales rep a question or request a demonstration, how long does it take for them to respond back? If you find your buying process to be slowed or hindered because your vendor is unable to deliver, this will be a strong indication of their ongoing customer service.

Find a vendor that can see the big picture.

Most businesses have more than one system to support their production. For you, if all the different parts do not move in harmony, you will be left with more headache than efficiency. Find a vendor that is willing to partner with other software systems to ensure the end result is a positive one.

A good vendor will ask questions to understand the important systems you are currently using and how they impact production so that you have everything you need. It is important that they keep you focused on the primary goals and help you identify future opportunities for additional functionality or system integrations.

By focusing on a vendor that will care enough to ask questions about your most costly production issues and your long-term goals, you will be sure to succeed. You don’t need someone that will tell you they can do everything, because you don’t need everything. You need a vendor that has the expertise and the experience to guide you through a successful project, while also taking into account what is best for you and your shop, not just their bottom line.


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!

The 5 Reasons Why Everyone Hates Manufacturing Software

The 5 Reasons Why Everyone Hates Manufacturing Software

No one enjoys researching shop floor systems. You have plenty of other responsibilities on your plate and frankly, you didn’t get into manufacturing to browse software recommendation websites.

We’ve compiled the 5 most common reasons people hate researching manufacturing software, the red flags to avoid and recommendations for success.

Continue reading

Unlock Smart Manufacturing and Production Visibility with an MES

Once you cut through the hype-cycle surrounding Smart Manufacturing you will find that, if implemented properly, going Smart grants manufacturers the ability to identify the true sources of their woes at the click of a mouse.

What the hype misses, but more and more manufacturers are discovering, is the critical role MES (Manufacturing Execution Systems) platforms like Quantum play in solution-focused Smart Manufacturing. Collecting data isn’t enough. Solving problems and optimizing production requires the production control and visibility available only with dedicated manufacturing software.

Adding Production Value with an MES

With an MES supported by Smart production data, manufacturers will:

  • Make intelligent connections using critical production data

Many companies struggle to decide where to store and use the Smart Manufacturing data. While their ERP can generate reports, it’s too far upstream in the manufacturing workflow to add value to production. A production-focused MES provides the workflow connections necessary to capitalize on the data, quickly identifying problems and implementing solutions. For example, if a machine goes down an MES will jump into action, rerouting work to maintain the shipping schedule.

  • Turn raw data into profit

Data alone won’t accelerate production or increase profit. You need to connect the data to the production insight provided by an MES to make a rapid, positive impact on production. In the previous example, if the machine goes down your MES will allow you to see the operation and actions taken that resulted in the problem. Supervisors can adjust processes to eliminate the problem in the future. When a line goes down, you can see the impact on production and evaluate the cost and benefit of solution options. Raw data is just information. An MES turns data into profit.

  • Create feedback loops to increase production

The goal of Smart Manufacturing isn’t better reports. You need to increase production and efficiency, and eliminate errors and waste. Smart Manufacturing solutions rely on getting critical information to the people who need the data to positively impact production; this is the primary role of any MES. With an MES, you can create feedback loops in the production value chain to shorten the time between the identification of a problem and the resolution. When a problem happens, an alert in the software is immediately sent so action can be taken quickly. There’s no need to search for information or wait for answers.

Unlock Smart Manufacturing

The foundation of Smart Manufacturing is turning production visibility and manufacturing insight into increased profit and efficiency.

Simply collecting data and running reports isn’t enough. Smart manufacturers turn insight into action that solves problems, generates revenue, eliminates errors, and accelerates throughput. An MES and dedicated manufacturing software includes the tools manufacturers need to take action on Smart Manufacturing data.

If you would like to learn more, or see how your company can quickly implement manufacturing software and Smart Manufacturing for a rapid ROI, contact CIMx Software to speak with an Application Specialist. We’re always happy to help.

Bridging the Gap between Your PLM and Manufacturing

Manufacturing and engineering are both symbiotic and disjointed. While manufacturing relies on engineering to do their work, engineers are not trained to provide manufacturing exactly what they need at the design phase; that’s further downstream.

These key differences require a bridge between the PLM tools in engineering and production operations on the shop floor.

It All Starts in Design

Engineers create a long list of documents during product design to ensure a product meets the customer’s needs and can be manufactured with the available materials, tools, machinery and people. Different products require different levels of complexity, including drawings, specifications, designs, materials, measurements and other detailed lists of requirements. A Product Lifecycle Management (PLM) system keeps all the information organized for the engineer.

This diversity, however, makes it more difficult for manufacturing, where work moves quickly and there’s not a lot of time to read. The PLM that was so useful during design cannot break down the work into operator-sized information packets for the shop floor.

Manufacturing Pushes the Pace

Manufacturing operates at a much faster pace than engineering. The shop floor doesn’t have time to digest complex information before beginning production. Even in the most labor-intensive, discrete production environments, operators work at the fastest possible pace.

Operators don’t have time to search for information on a drawing or spec sheet. If it’s not on the screen when operators need it, productivity and profitability fall drastically. Even a few minutes spent searching can make the difference between a profitable production run and a project overrun.

Manufacturers need to manage the production process with speed and precision; design engineers need details that inherently slow that production down.

Where is the Bridge?

The bridge lies between design and manufacturing. Design and manufacturing get the specific tools they need to do their jobs – tools that are significantly different.

  • PLM design is absolutely required in most modern, complex manufacturing settings. Complete control of engineering design increases competitiveness of the resulting product.
  • Engineering design for complex manufacturing can’t be done by the transactional ERP.
  • Current PLM product offerings meant to work in manufacturing require far too many interactions by the operators to be effective.
  • Companies need bi-directional data transfer between design and manufacturing. Production should provide valuable feedback to design.
  • Traditional MES systems (used on manufacturing shop floors) struggle to get information back to the PLM.

A Solution for Both Manufacturing and Design

Without the proper design, production can’t build correctly and without the detailed instructions, production can’t do its work. There is no sacrifice here that will work. As engineering information flows to the shop floor already, this part of the equation is complete. What’s missing is the critical link for manufacturing back to design and manufacturing engineering (there are holes in both areas traditionally).

What Can Help?

ERP systems can’t. These are transactional systems that will force the design and manufacturing engineers to separate every production step or list them as a single step without the associated, “nested” details that are so critical to the operators.

PLM systems can’t. We’ve already seen how these systems manage documents, but not the associated instructions. Operators can’t build from the documents, as they don’t have the time or experience, typically, to differentiate what specific work needs to be done at each step.

This leaves just the MES and even at that, most MES systems won’t touch the PLM without extensive programming and customization. Manufacturers also need process enforcement, work center or operator-based work instructions, quality control and access to all the PLM documentation that’s required to do the job.

Recently, we introduced a product platform that makes live communication between the PLM and the MES a reality, without the requirement for customization. While we understand many of the problems facing manufacturers, digging into this problem, we’ve found that we have only scratched the surface. Plenty of additional problems exist in connecting systems in the manufacturing environment. What other issues do you have? We’re interested to know.

Our goal is to break down the walls between engineering, design and the shop floor. That is where we see the real power of the Smart Factory or Manufacturing 2.0. Visit us online at www.CIMx.com and let us know what your biggest challenges are.

Calculate the Benefit of Innovation in your Manufacturing Software

Optimize your investment with a disciplined approach to judging innovation in MOM, MES and paperless manufacturing systems using a few simple tips.

By David Oeters, Corporate Communications with CIMx Software

The other day I bought a new cheese slicer. Of the 4 or 5 different models, I choose one with an “innovative” design. I like innovation (who doesn’t?) and figured it HAD to be better.

How can you be sure you are optimizing the benefits of innovation in your manufacturing software? Illustration by www.colourbox.com

How can you be sure you are optimizing the benefits of innovation in your manufacturing software? Illustration by http://www.colourbox.com

The first “innovation” was an ergonomic handle with an odd swirl of rubber and ridges for my palm, and I hated it. It was designed for a much smaller chef, because the swirl put my fingers in a vise and the ridges dug into my palm. The other innovation turned out to be an adjustable cutting guide that actually worked, letting me control the width of the slice – opening up a whole new vista of cheese slicing delight!

I know the term “innovation” has become white noise in the manufacturing tech industry. Everyone uses it, and all sales copy includes (what does this mean) variants of the term (innovation, innovative, revolutionary, advanced… blah, blah blah…). There is a real need for innovation in manufacturing software, especially MES and MOM systems. Our industry is grappling with accelerating change – new technologies, customer expectations, market shifts, new regulations, and more. Innovation is a strategic advantage, and can be the difference between barely surviving and thriving. To manage change, manufacturers need suppliers who innovate.

Ignoring the marketing to discover true production benefit in innovation can be an almost impossible task. Companies duped by innovation promises may end up with a system that never works as promised, or with a system that can’t adapt as your manufacturing needs change.

Here are five questions to help you determine the benefit in manufacturing software systems:

  • Does the innovation add real benefit?

Innovation is about recognizing a need and applying a solution. A key element of that simple equation is NEED. Adding complexity, cost, or processes to a system isn’t innovation if it’s not addressing a need. In fact, increasing complexity is counter-intuitive to innovation.

  • Is the innovation built on a solid foundation?

An adjustable cutting guide on a cheese slicer that doesn’t slice cheese isn’t really a benefit. Likewise, an innovative reporting system on an MES that doesn’t offer shop floor control isn’t useful. Don’t get distracted by marketing. Make sure the system is built on a solid foundation and effective solutions.

  • Is the supplier “buying” innovation?

As a company grows, it becomes more difficult to innovate. Innovation requires agility you don’t find in massive corporations. This leads some big companies to buy smaller companies and products for their innovation. They package the systems together and call it “revolutionary” and innovative. Don’t be fooled. Real innovation doesn’t come from throwing software products together. It requires organic growth and development after the “Eureka” moment.

  • Where will the innovation go from here?

It’s important to see an innovative new feature or function as part of a cohesive product. Many failed innovations never find a fit in the processes offered by the overall product, especially in a software ecosystem. Consider the struggles Apple is currently having with the Apple Watch. It is an innovative product, but many consumers struggle to see how it fits in the overall Apple ecosystem. You shouldn’t have to wonder how to use a feature.


As manufacturers grapple with change, innovation from software suppliers will be of strategic importance. You need a MOM or MES system that is agile, flexible, adaptable, and easy-to-use. Software companies can’t just “promise” innovation, they need to show it. Hopefully, the questions above will help you evaluate suppliers who promise innovation.

Want to learn more, or see how paperless manufacturing can add immediate production benefits and revolutionize your shop floor. Contact CIMx today for a free shop floor evaluation.