Tag Archives: quality improvement

Simple Steps to Improve Production Quality

By David Oeters, Corporate Communications with CIMx Software

Every manufacturer struggles to improve quality during production.  Any level of defect is unacceptable, causing scrap, rework, missed ship dates, and lost profit.  Quality defects can cause a host of other problems more difficult to measure; including customer’s losing confidence in your product and frustration on the operations team.

While you may have a team working hard to improve quality assurance and quality control, manufacturers must be judicious in pursuing increased quality.  With any quality program, there are diminishing returns for the initiatives.  Adding more people to Quality Control, or creating additional checklists for production, will not always bring an acceptable return.

However, there are simple steps you can take to bring sustainable improvements in quality and provide a solid foundation for future initiatives.

A Closer Look at Manufacturing Quality

There are two distinct aspects to production quality.

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Continuous sustainable quality improvement is only possible with a digital system. Illustration by www,colourbox.com

Quality assurance is usually defined as the management of the quality of parts, materials, tools, production engineering plans, production processes and all aspects of the work flow.  Quality assurance focuses on the proactive preparation for the release of orders, eliminating common sources of errors by guaranteeing inventory and tooling is available and creating of easily understood production instructions.  These are two critical elements to support an efficient production process.

The other aspect of production quality is Quality Control, commonly defined as the data collection measurements and inspections made during production to ensure products meet or exceeds specifications.  Quality control requires accurate measurements be taken during production, and a record made of all metrics in the engineering specifications.  By identifying and eliminating defects early, before they become more serious and costly, overall workflow and production performance is improved.

Simple Steps to Improve Production Quality

Manufacturers using paper to manage quality and production are creating an environment with a high risk of quality defects.  Paper simply cannot adequately support modern manufacturing, especially not as a tool in Quality Assurance and Quality Control.  Companies relying on paper will see limited improvement in manufacturing quality, but larger gains are impossible due to the fundamental flaws of using paper to manage production.  Build books filled with brief instructions and difficult-to-understand steps printed off a few hours earlier, and quality measurements hastily scribbled on sheets of paper do nothing to control or manage quality.

Continuous sustainable quality improvement starts by eliminating paper from the production process and transitioning to Paperless Manufacturing.  Consider these simple steps:

  • Convert the paper environment to a digital environment.

There’s no need to recreate your work instructions.  Move your existing, corrected instructions to a digital format that can quickly be accessed by engineering as they are planning.  The shop floor benefits with revision controlled, accurate work instructions and multimedia production assistance when needed.

  • Integrate production information from inventory management to shipping.

Incorporate all production documents and data in common records that can be accessed when and where they are needed.  Eliminate the struggle production has in finding information when they need it, by linking relevant data to each operation.

  • Use digital methods to assure and control quality at every step.

Automatically collect data and ensure specifications are met. Shorten the time a defect is identified and corrected with automatic tolerance and a closed loop disposition system.  Create proactive alerts for inventory shortage, machine issues, or bottlenecks.

Companies that have embraced paperless manufacturing have seen their production quality increase, often dramatically, by using readily-available technology to aid, manage and control the materials and process steps of the work flow.  Automating the process of collecting metrics and responding to defects at the point of occurrence isn’t difficult, and will improve quality and profitability.  Unlike systems that only target specific areas of the manufacturing value chain, paperless manufacturing provides a solid foundation to improving both Quality Assurance and Quality Control across the production workflow.

Contact CIMx Software to see how Paperless Manufacturing can improve quality for you.

Tips to Stay Focused on Production Improvement in 2017

By Liz Hamedi, Customer Experience Specialist with CIMx Software

Every New Year there is a behavior cycle that begins among manufacturers and manufacturing software providers.

Manufacturers reach out to software and solution providers at the beginning of the year to solve their production problems and eliminate the frustrations.  Problems are holding their business and production back.  It’s a New Year and time for a new start, they tell us, and the company is motivated to get something done.

As the year goes on, they lose focus and start making excuses.  The project is too big, or not what they expected or some other problem took precedence.  By the end of the year, they end up right where they were the previous year, and the cycle begins again.

The solution, and improved production, is closer than these companies realize. For 2017, our goal is to deliver solutions that help manufacturers and improve efficiency.  From our experience, there are three reasons companies wait on a manufacturing software solution: money, risk and fear.

Eliminating Manufacturing Software Indecision

Money is a concern for every business.  Many software projects fail because the team focuses on the price tag and cost rather than the ROI.  Years ago, when all software solutions were exorbitantly priced and complex, the ROI was measured in years.  Today, with the advent of modern software technology, a powerful off-the-shelf software solution will deliver an ROI in less than 9 months.  Start your project by considering what the problems you want to solve cost the business.  Look for a system that will solve problems and fit your budget. Look at the value beyond the initial price tag and consider the ROI. Software won’t only solve problems, but accumulate value.

3d small people - rolls gear

Want to improve production? Stay focused on proactive improvements, rather than reactive solutions. Illustration by http://www.colourbox.com

Risk keeps many projects from ever starting, even when there is a compelling need for a solution. Many Manufacturers recognize change is needed, but without a guaranteed benefit they hesitate.  In their mind, a software solution is a factor they can’t adequately anticipate, and a failed project can negatively impact the whole business.  Today, there are steps a company can take to minimize risk.  Start with a pilot program.  Test the software in a single area or production line before rolling it out to the whole plant.  Look for software that supports an agile phased implementation, helping minimize disruption and allowing for greater control of the implementation process.

Fear motivates many manufacturers to find excuses rather than solve problems. Many fear the software solution will be worse than their current situation.  They fear the impact on the company and co-workers.  They fear the resource cost – IT is already overworked and understaffed, and there is no way they can possibly support another system.  There may be other problems, such as outdated planning or an existing software system that may be difficult to integrate, causing hesitation.  Identify these fears early in the process and engage the software supplier in a solution. Often through open dialogue you will discover the solution is much easier than you think.

A Promise for Improved Production

Make 2017 the year you eliminate errors and modernize your manufacturing operations.  At CIMx, we’re here to walk with you every step of the way.  For many, the first step is the hardest, but once you identify a solution, the benefit will greatly exceed the cost.

Reach out to CIMx today and discover how we can solve your production problems and deliver benefits and results in 2017.

Improving Quality with Paperless Manufacturing

As manufacturers struggle to reduce costs and improve production, more and more companies are turning to paperless manufacturing to improve quality.

By David Oeters, Corporate Communications with CIMx Software

As production grows increasingly more complex the Cost of Quality (COQ) is also increasing, with some companies reporting costs as high as 10% of revenue. The indirect and soft COQ may be even higher as you consider the non-value added time necessary to evaluate and address quality escapes.

When manufacturers consider initiatives to lower costs, quality is an emphasis. Modern MES and paperless manufacturing systems are delivering tremendous value to companies focused on improving quality.

MES and Quality Improvement

Quality.

A robust MES provides a solid foundation for improving quality. Illustration by http://www.colourbox.com

According to a white paper by Renaissance Services, the foundation of all quality escapes is the inability of the manufacturer to manage the details of production. The primary focus of paperless manufacturing and an MES is managing details through automation or providing the correct information at the right time and place in the production. Consider how paperless manufacturing addresses common sources of production errors:

  • Planning errors.

This could be the wrong plans or the wrong technical specifications. Many of these are paper-based errors, and occur when the wrong plans are used, or critical information is missing from the work packet. An MES will ensure the proper planning and revision control, and make accessible all the information the shop floor needs at any time.

  • Errors in approvals.

The approval process relies on communication and collaboration. Without a single source of manufacturing truth or a structure for communication and collaboration in the production process, errors occur during approval. Shortcuts are taken during approval, as the effort to coordinate the process increases. Improved quality relies on a disciplined approval process.

  • Missing documentation from the Technical Data Package (TDP).

Many times with paper-based planning, documentation is left out because it isn’t considered necessary. This is especially true of the TDP. Critical documentation from the first article inspections is ignored or buried to reduce complexity or to speed up production and get a product to market – leading to errors.

  • Ambiguity in the technical requirements.

Without automated quality checks during the production process, any ambiguity in specifications can lead to a critical quality error. For example, when a shop floor uses a paper spreadsheet to record production data, there’s no real time feedback loop on quality checks, and errors will occur. Quality assurance will find the error too late for corrective action.

  • Requirements that are overlooked in production.

This comes down to inadequate documentation and processes during production. Requirements are inadequately communicated to the shop floor, or aren’t accounted for in the planning. Without real time quality checks or a method of managing production, critical requirements are ignored until problems occur.

  • Changes in standard processes, especially special processes, in the production cycle.
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Are you confident in your quality control plans? Illustration by www,colourbox.com

Process enforcement in an MES or paperless manufacturing system ensures the shortcuts that often creep into manufacturing process are eliminated by ensuring documentation is reviewed and work signed off before planning is released. Without process enforcement, the shop floor will rely on processes they know, not the correct processes.

  • Quality escapes that slip through inadequate first article inspections.

Often in paper-based or unstructured first article inspections, critical details can be lost, or there is an assumption on how work will be completed. This is especially true as the number of first article inspections increase at a site. Without adequate time, corners will be cut. With the automated records and audit reports created in an MES, critical details aren’t lost and are automatically recorded for future use, and the shop floor has more time to properly conduct a first article inspection.

 Smart Manufacturing and the Future of Production

As complexity has increased in production, and the tolerance for errors has decreased, manufacturers can no longer adequately manage the information and detail necessary using error-prone paper planning and inefficient processes. Manufacturers need a comprehensive system to manage production.

Manufacturing needs aren’t slowing down. The complexity and technical requirements of manufacturing are increasing. Consider Smart Manufacturing – the integrated technology and systems essential for advanced Smart Manufacturing require an MES to manage production. Excel spreadsheets and Word documents simply can’t manage complex manufacturing processes.

Want to learn more, or see how a shop floor software system can improve your shop floor? Contact CIMx today for a free shop floor analysis to learn more.

5 Keys to Effective Shop Floor Data Collection

Want to Increase quality, improve production and increase profitability? An effective shop floor data collection will do all this and more, and is much easier to implement than you think.

By David Oeters, Corporate Communications with CIMx Software

How effective is your shop floor data collection? Illustration by www.colourbox.com

How effective is your shop floor data collection? Illustration by http://www.colourbox.com

How important is quality to manufacturing? According to a recent study, it may be the most critical factor in manufacturing profitability. A 1% to 2% increase in productivity may represent more product, but a 1% to 2% increase in quality represents less waste, less scrap, more product, more productivity, more efficiency, and happier customers.

Data collection provides the foundation for quality improvement in manufacturing, and every manufacturer has a quality team or processes in place, yet many companies never realize the full benefit of quality improvement due to ineffective data collection. They struggle to turn the data they collect into real benefit or measurable improvement. In fact, many times inefficient data collection will lead to errors, additional scrap and waste, as well as lost production.

Take a moment to evaluate your current plan for data collection using the follow criteria to identify areas for potential improvement:

  • How “smart” is your data collection?

A smart data collection program is proactive. By catching and eliminating errors early, you can minimize waste and save money and production. A “dumb” data collection delays review of the data, or may not have a plan in place to take corrective action. Looking at a report of mistakes a month after they happened highlights a month of lost opportunity for improvement, and leaves the cause of errors in place.

  • Does your data collection include automatic tolerance checks?

Automating as much of the data collection and check-off process as possible removes potential sources of errors and keeps shop floor employees and the quality team focused on critical tasks. For example, automating tolerance checks will identify quality escapes the minute data is collected. Comparing collected data against the engineering specs is best left to the software system.

  • Does your system eliminate potential input errors?

The truth is, your data is only as good as the system used to collect it. How many times do you input the data? Any more than once is a sign of wasted effort and increased errors. How long do you wait to input the data? What is your source for the data? If you wait till the end of a shop floor shift, when data is collected from handwritten notes on the traveler, then you have a problem. The data you are using is unreliable, out-of-date, and is costing you money. Look for ways to streamline and improve the reliability of your data collection and input.

  • Do you have access to real-time reports?

With modern manufacturing tools and advances in software and technology, there is no reason why the shop floor shouldn’t have access to real-time reports. Today, you can implement a low-cost and low-risk paperless manufacturing system in less than a month, and have a dashboard with real-time shop floor visibility and quality control soon after. With an automated system, you can also move the people who once assembled reports onto more important tasks.

  • How are you using the data that’s collected?

Consider when you are collecting data. Many times a company will collect data once all the work is done. Unfortunately, this data is collected too late to take corrective action. It’s true, this data can be used in an audit or to eliminate a defective product, but both the work and materials are wasted, and planning and shop floor scheduling is unreliable as product is pulled after production. Consider when you can best utilize the data, and when it should be taken. Look at the reasons why you aren’t getting the data you need when you need it. Taking a few moments to collect shop floor data during production is time well spent.


The goal for all manufacturers should be continuous improvement toward optimal production given the machines, equipment and processes being used.  The single most important requirement to achieve that goal is continuous monitoring of shop floor results.  Collection of result data that is automatically verified against specifications and available to decision makers who are tracking progress of all work orders across the shop floor is the best way to continually monitor production and achieve continuous improvement. Give CIMx a call today or leave us a message and ask for a free review of your shop floor processes and a plan to optimize production flow.