Tag Archives: production data

Process Improvement graph.

Use Your Data for Accurate Production Costs

For manufacturers, accurate estimates are critical to managing costs and margins. If estimates are based on guesswork: bids can be lost, delivery times missed or costs can spiral out of control. Too often, operators will pencil-whip work times on their way out the door rather than accurately tracking and recording their work. This skews the limited data available causing misinformed directives from the top.  When both the historical data and the analytics at the foundation of estimates are suspect, problems quietly grow costing the company money that has to be made up in additional production.

Turn Production Data into Profit

Accurate estimates require both clean historical data and production visibility, both of which are provided by the Quantum Production Control System (PCS). Let’s look at a few areas a PCS can enhance your estimates:

  • Accurate Labor and Production Data

Know who did what and for how long during production, and then turn that data into more precise estimates. The PCS automatically tracks labor and production through standard use of the system. This includes machine time and labor, so management can see how much time, effort, materials and parts are required to complete work. Over time, as accurate data is accumulated, the company can begin providing more accurate estimates and labor loading.

  • Identify and eliminate scrap

Scrap can turn profitable products into an expense for manufacturers, and yet many companies struggle to understand the cause. The production control system collects production data that reveals where and how scrap is generated. The PCS links the scrap to the work being done at the time it occurs. With this information, the manufacturer can either eliminate the root cause of scrap, or better estimate standard losses in production.

  • Focus on profitable work

Once you are tracking labor and production costs, leverage the data to identify and prioritize the most profitable work. Refine your gross manufacturing margin using production data to identify products and goods with a higher gross margin. With this information, you can make more profit on every sale and shipment. The company makes more and spends less.

Increasing Profit Velocity

Many companies look at a production control system to solve a specific problem such as a failed audit, late shipments, or poor visibility into Work in Progress (WIP). Even with the solution in place, the company finds more value in the critical data the system feeds to the sale and production cycle. With higher gross margins, accurate estimates, and control over scrap and production the company finds expenses go down and profits up.

If you’re ready to take control of production costs and enhance your profit on every product built, contact CIMx Software today to learn more about Quantum. Discover what a PCS can do for you.

How to Turn your KPIs into Profit and Production

There’s an old saying, “If you can measure it, you can manage it.”

Manufacturers with Production Control Systems (PCS) know the truth of that saying. With the PCS providing the real-time data and process control, these companies supercharge their Key Performance Indicators (KPIs) with real-time data to accurately track and measure shop floor progress. That real-time data turns KPIs from an instrument of observation to a tool for radically accelerating and sustaining production while generating profit.

Turn Raw Production Data into Efficient Operations

Here are four ways real-time data and KPIs deliver powerful benefits for manufacturers:

  • Accelerate and sustain continuous improvement programs.

Continuous improvement is critical, but many companies have difficulty maintaining progress once the program is over. New behaviors are difficult to maintain, and old habits die hard. KPIs allow the company and team members to monitor the progress. Your team can use that real-time data to support improvements long after the program is over. With everyone sharing the KPI and monitoring progress, collaboration increases and success is shared.

  • Benchmark performance to identify areas for improvement.

Use KPIs to benchmark and compare areas of the business. Identify underperforming areas and discover what works in areas of high-performance. With that insight, you’ll discover those slight adjustments that pay big dividends. For example, higher scrap and non-conformance rates at certain operations may indicate machines or tools that require maintenance, or a problem with a supplier. Target and eliminate the problems for a positive net effect across the production value chain.

  • Identify higher profit work

KPIs are an excellent way to evaluate production data in real-time, revealing the inefficiencies that cripple profit margins if left unchecked. For example, Estimated versus Actual production times, a common KPI, identify products that consume more resources than expected, delivering a lower profit. By focusing on higher-profit work, the company generates more revenue for less effort.

  • Evaluate planned workarounds

When an issue occurs in production, supervisors will implement planned workarounds that often result in more problems than they solve. KPIs monitor progress as the workaround is implemented. Evaluate the solution in real-time and implement additional changes as needed to maintain progress. With KPIs, the orders stay on schedule and ship dates aren’t missed.

Turn Real-time Data into Production and Profit

Most, if not all, manufacturers utilize Key Performance Indicators to monitor production. The difference for manufacturers with a Production Control System in place is the real-time data that fuels the KPI. Supervisors and management track and monitor production, accessing critical KPIs from anywhere. The PCS makes the company more agile, able to control production and manage work. The shop floor reacts to issues and opportunities as they happen, rather than studying events in a report a day later.

Contact CIMx today to see how Quantum can supercharge your KPIs and reports with real-time data to accelerate production and profit for your business.

5 Powerful Benefits of Production Data Visibility

By David Oeters, Corporate Communications with CIMx Software

Production data fuels the manufacturing industry. Putting this strategic information to work adds profit and production to your business.

As employees collect and use data locally in a wide variety of homegrown formats, data silos are created diminishing the overall value of production information. Over time, competing spreadsheets and shared drives of disconnected production data create inefficiencies and errors. The problem is as much cultural as technological, preventing alignment between sales and operations.

Align Sales and Operations with Data

Unlock the business value of your data by making it accessible across the enterprise. Here are five reasons why data visibility and aligning production databases must be your next improvement project:

  • Work from a single source of production truth

Employees use guesswork and estimates if they can’t find the data they need. This leads to errors and mistakes. With a single source of accurate and accessible production information, there’s no need to guess. Employees work faster with critical information at their fingertips.

  • Eliminate redundant data entry

If sales, operations and dispatch all keep their own spreadsheets tracking related elements you end up with employees doing the same work again and again. Redundant data entry is error-prone and creates waste. Eliminate wasted time and focus on value-added work when you adopt comprehensive, modern data collection standards.

  • Provide revision-controlled, accurate information

Many companies struggle with document and change management. Inaccurate and outdated work instructions and production data create errors and frustration. With documentation under revision control, you can better manage change. Employees work with confidence knowing they have the most accurate and complete production information.

  • Work from a single screen

According to a recent survey, shop floor workers waste 30 minutes to 2 hours every day looking for information. With a single production database and data visibility, employees make data-driven decisions to increase productivity and respond accurately to change.

  • Align the business from shop floor to top floor

Manufacturers identify alignment between sales and operations as a critical business need. Collaboration requires everyone working toward the same goals, with the same vision of the business. Foster collaboration and alignment by linking sales and operations with accurate production data.

Empowered, Data-Driven Manufacturing

Data visibility is the foundation of increased output and business growth. Data collection standards provide the basis of sustainable process improvement and business collaboration.

Start by eliminating the silos and moving your historical data to a manufacturing system. If possible, convert your data to object-oriented files so you can begin running reports on it, providing the trending and analysis that is the foundation of data-driven, Smart Manufacturing.

Want to learn more, or see how a Data Migration Engine can eliminate data silos and empower an MES to do more for manufacturing and production? Contact CIMx today to talk to an Application Engineer about Quantum and learn how to unleash your production data for higher output and profit.

How Much Can You Trust Your KPIs?

There is more to effective manufacturing analytics than reports. You need an effective and efficient process for collecting data.

By David Oeters, Corporate Communications with CIMx Software

Manufacturing is changing.

3d small people - way choice

Are you using data to optimize production?  Illustration by http://www.colourbox.com

In the past, it was enough to write a few notes on the traveler, type them into a spreadsheet at the end of the day and print up a report. As long as work was completed and product moved, a shop floor could get by.

With the advent of new technology, smart manufacturing, and a digital foundation for production, paper-based data collection is no longer sufficient to support the shop floor. With paper, you can’t easily access the relevant analytics to support process improvement and collaborative manufacturing. There’s no reason not to have relevant and actionable data on production, and a plan to optimize the shop floor.

While reports are important to shop floor optimization, a process to collect the data, relevant data, is equally important. Consider these questions as you review your shop floor analytics program:

  • How is the data being collected?

If you implement a shop floor system to collect and collate data, but still rely on scribbled notes on the traveler or an operator’s memory, then your reporting system is never going to be as effective or efficient as you need.  Transcription errors or missing data may also compromise the accuracy and usefulness.

  • Are you collecting data in all the relevant areas of the process?

Knowing a product has a non-conformance is important for your customer; you also need to know the root cause of the quality escape. Knowing where the non-conformance occurred is a critical step for process improvement. You need to collect data throughout production, not just at completion.

  • Are there holes in the data collection?

Many companies focus their data collection on machines. Pulling data from a machine is easy, but many times non-conformances occur at other points in the manufacturing process. Without data collected at every operation and every critical step, you’re faced with questions on when and how a non-conformance occurred.

  • Quality.

    An MES will not only collect data, but give your data relevance. Illustration by http://www.colourbox.com

    Is the data you are collecting relevant?

Data needs perspective and context to be relevant. An MES provides a framework for manufacturing. The data collected is automatically contextualized with a process, becoming more than a single point in production. It becomes an element in a process.

Giving Production Data Relevance

An MES creates a foundation that both collects the data and gives it relevant perspective. It provides a way to seamlessly, and many times automatically, collect data in real time during the production process.

Data collected is connected to an operation, a production, a work order, and to an operator. You can see the events preceding the data collection and the events following.

If you’re still struggling to peel back the layers in your manufacturing process and understand the root factors in operations, then contact CIMx today for a free shop analysis to see what data an MES can reveal for you.

A New Vision of Mobile Manufacturing

Don’t be fooled, mobile manufacturing requires more than just an app.  It requires an integrated mobile solution delivering shop floor functionality on the go.

By David Oeters, Corporate Communications with CIMx Software

I love music.  A few years ago I wanted a new stereo system.  I had a single requirement – I wanted to use my MP3 player with the sound system.  I wanted to throw parties, fill the house with music that fuels the fun.  Problem was – I didn’t do my research.  I bought a system with the words “MP3 Compatible” in big, bold letters on the box.

Unfortunately, “MP3 Compatible” meant a single USB port.  The stupid thing never worked, and was about as functional as fins on a kangaroo.  I couldn’t plug my player directly into the port.  Instead, I had to download my music onto an empty zip drive.  Then I had to plug the zip drive into the USB port.  After a few minutes, a song MIGHT start playing.  Maybe.  I couldn’t control the music, and between songs there was a LONG delay.  If I ever downloaded something other than music, an error would flash and the whole system shut down.

Honestly, the system and my music player were as compatible as fire and ice, and as functional as those fins.  I felt cheated, used and angry.  My excitement crumbled as the truth of my purchase became apparent.

What can mobile manufacturing do for you?

Using a tablet, smart phone, or other mobile device to access a true paperless manufacturing system will boost productivity, help eliminate errors, and increase work flow visibility.  Imagine giving your shop floor anytime and anywhere connection to production documents, including work orders, safety documents, training videos and more.  How much more productive will your team be if QA conducts real-time quality checks from anywhere?  How would shop management like anywhere access to real-time production data?

Can your manufacturing software support mobility on your shop floor? Image  by www.colourbox.com

Can your manufacturing software support mobility on your shop floor? Image by http://www.colourbox.com

Unfortunately, many MES or paperless manufacturing vendors make promises regarding “mobile manufacturing compatibility” that fool many companies into accepting awkward functionality and systems that never work as promised.  Compatibility between a shop floor system and mobile devices is neither important nor useful, compatibility between the application software and the work flow processes is how you achieve true mobility.  You need a scalable, adaptable solution that supports your work flow processes.

For some vendors, “mobile manufacturing” is a simple app that provides a view of some production data from a mobile device.  Turn on the app and you can see shop floor trends, and maybe identify potential shop floor problems, but that’s about it.   These apps might allow you to open a document from your web device, see the production schedule, and maybe move an item on the screen, but that’s the limit of their app-functionality.

Other vendors promise mobile manufacturing as an add-on project once the initial project is complete. They can do it, if you want, but it leads to additional service fees, project schedule bloat, and complicated and risky implementation.  Like me and my “MP3 Compatible” sound system, manufacturers buy a system, only to see the limits of “compatibility” once they have the system on the shop floor.

True Mobile Manufacturing

True mobile manufacturing offers an integrated mobile solution within the core system, not an app.  The power of the complete manufacturing system should be available from most mobile devices, and offer interactive functionality, not just read-only screenshots of data.  Mobile manufacturing should ensure quick and easy access to your MES or paperless manufacturing system from almost any device.

How much more could you do with an integrated mobile solution on the shop floor?

How much more could you do with an integrated mobile solution on the shop floor?

Don’t be fooled.  Look for browser-based systems (though, be careful you aren’t diving head first into the dangerous world of the Cloud).  Look for systems that are fully compatible with the web, and offer complete mobile functionality, not an app or two.

The future of modern manufacturing is embracing mobility.  Even if you aren’t ready to give your shop floor a tablet now, in a few years (or less) you may need shop floor software that offers mobile manufacturing.  Take the time, do your research and find a solution with integrated mobile manufacturing, not just an app or hastily slapped-on “mobile compatibility.”

… unless you want to watch your dreams of an efficient, mobile shop floor crumble like my dream of music-fueled parties…

Let us know if you want to learn more or see how integrated mobile manufacturing can transform and benefit your shop floor.