Tag Archives: Production visibility

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.

5 Critical Benefits of Shop Floor Visibility

Do these common complaints sound familiar?

“I’m accountable to our customers. I need to know when an order is going to ship.”

“If I need to know what’s happening on the shop floor, no one can give me a straight answer.”

“When a problem happens, I’m the last one to know.”

A lack of production visibility underlies each of these problems. The profit-driver and central focus of a manufacturing business is production, but few companies have any idea what’s happening on the shop floor from one moment to the next.

The Blind Spot in Manufacturing

As we discussed in our last blog, How Much Does the Lack of Production Visibility Cost Manufacturers? companies utilize flawed systems, like their ERP, or error-prone processes, like paper records, to track and monitor production. Critical data and warning signs slip through the cracks, and their business struggles to retroactively fix problems rather than proactively grow the business, even as money and efficiency drain away. Without a dedicated workflow system like Smart Manufacturing to monitor and manage production, these companies will never have real-time production visibility.

Managing and Monitoring Production

A solution based on Smart Manufacturing provides real-time visibility and delivers benefits beyond a dashboard or a morning report. Data collected becomes the foundation of proactive production management, providing a positive impact across the business. For example:

  • Identify and track ship dates with pinpoint precision.

Quit paying overtime or fees for late shipments, and know with a single glance when an order will ship. With real-time production data, manufacturers can release an order and know with confidence when work will be complete. Scheduling bottlenecks aren’t a surprise, and adjustments to the schedule or routing can be made to eliminate problems before they occur. Get an update with a click of a button and stay on top of production to ensure orders ship on-time, every time.

  • Lower production costs.

On any shop floor, hidden inefficiencies will drain profit from every order. With real-time visibility, you can identify inefficiencies – operations that generate additional scrap, wasteful processes or employees that may need additional training – and implement solutions. With accurate, real-time visibility you lower costs across the production lifecycle, drastically reducing expenses.

  • Speedy, error-free New Product Introduction (NPI).

When complications and errors occur during NPI, frustrations and costs mount. As the company attempts to solve problems they may not fully understand, profit and production is lost. When an NPI is successful and the shop floor delivers at a lower bid, without defects and ahead of schedule, the manufacturer becomes a hero. With production visibility, manufacturers quickly identify, in real-time, where and when a problem occurs. Alternate work paths can be implemented and the result seen immediately – efficient and seamless NPI.

  • Sustainable process improvement.

For many manufacturers, process improvement is a waste of time and resources. After the initiative, the shop floor quickly reverts back to the comforts of less-efficient but more familiar processes. Real-time visibility not only supports process improvement by providing critical data for measuring success, but also provides the feedback loops shop floor employees need to utilize the improvements. Companies with real-time production visibility see sustainable, improved results with almost every improvement initiative.

  • Increased quality and lower scrap and waste.

Quality escapes, scrap and waste put a manufacturer at risk. With real-time production visibility, the shop floor receives immediate feedback on quality, and products that don’t meet engineering specifications are quickly identified for rework. With immediate feedback, operators can see the processes that work and the processes that result in escapes. Manufacturers with real-time visibility quickly achieve higher output, increased quality and the elimination of scrap and waste.

Turning Visibility into Increased Margins and Output

If you’re ready to quit making mistakes and errors, and optimize your profit, production and efficiency, then contact CIMx Software to see how quickly a Smart Manufacturing system can give you real-time production visibility while eliminating errors and manufacturing problems.

For most manufacturers, it’s a few simple steps to move to a Smart Manufacturing system. Processes currently draining resources and effort can be automated while error-prone paper methods can be shifted to a digital system. Collect and organize the data in real-time, rather than after work is complete and start manufacturing smarter today.

Take the first step toward Smart Manufacturing by contacting CIMx today at www.cimx.com.

How much Does the Lack of Production Visibility Cost Manufacturers?

When mistakes occur on the shop floor – a part doesn’t meet specifications or a piece is out of tolerance – manufacturers pay in lost profit and slowed production. The longer it takes to identify the error and implement a solution, the more damage is done to your business by excessive waste and angry customers.

If you miss the problem and ship a faulty product, customers will find a different manufacturer. How many mistakes are going unnoticed on your shop floor right now? At what point in production does a non-compliance occur? Can you assure a customer it was the last time they’ll see this issue?

The underlying problem is a lack of production visibility – a problem for many manufacturers. This leads to a lack of conformance and control, and costs the business money. Efficient production operations require production visibility. When your ERP’s blind spot is the shop floor, companies throw away resources and effort every day and on every order.

Capturing Critical Production Data

The problem isn’t effort on the shop floor; it’s the tools being used to provide production visibility.

Paper is a black hole for visibility with data collected by paper almost unusable. The data provides a false sense of security – companies believe the data collection solves problems when in reality it is masking them. Even when the data finds its way to a report the data must be viewed with skepticism – data on paper is ripe for mistakes. The work and effort necessary to collect and collate paper-based data is wasted, especially when you consider the high potential for inaccuracy.

Many companies prioritize the collection of machine data. Machine data provides a limited view of production processes, often after mistakes and errors have been made. You need data on your labor force for the complete story on production.

Many companies mistakenly rely on their ERP for production reporting. ERP systems struggle to adequately track and manage work. As a transactional system, the ERP works upstream in the production value chain. It manages orders and financial transactions, but it can’t capture the nuance or cause-and-effect links required in a workflow. Companies relying on their ERP for production have a dangerously flawed view of production, resulting in squandered opportunities and wasted resources.

Manufacturing Software as a Window to the Shop Floor

For real-time production visibility, you need a workflow-based system that represents the interaction between the materials, people and processes that fuel production. These Smart Manufacturing systems predict when and what proactive effort will improve output and efficiency. Forward looking, rather than reactive, it gives manufacturers the power to deliver just-in-time response to issues. It’s more than a simple snapshot of production, but rather a comprehensive view of operations. Smart Manufacturing systems deliver less downtime and scrap, and higher output, efficiency and quality.

By linking your ERP to Smart software supporting and managing shop floor operations, the ERP has the real-time production data it needs to operate efficiently without clogging the smooth upstream operation of the business. The sales and customer-service team can consult scheduled ship dates from the MES data to accurately assess when an order will be completed. Production supervisors and the shop floor team utilize software designed to support their unique workflow needs without navigating the transactional processes required in an ERP.

Get back control of the shop floor and know, with certainty, when and where mistakes happen. Manage the shop floor through a workflow system, and not notes on a traveler or bits of data coaxed out of an ERP.

Learn more about the real-time production visibility and workflow-based software in Quantum by contact CIMx at www.cimx.com.