Just knowing an alert has occurred and sending it to a human user may not be the ideal outcome. Again, just like in the previous sections, depending on humans to handle tasks introduces variability and more important, excess cost. Let’s look at an example of a machine that is experiencing abnormally high hydraulic temperature. We have determined this is abnormal based on the specific machine, the in context item / part specific parameters and perhaps external sensors such as ambient temperature. An alert gets raised . . .Read More
With huge amounts of data coming in from machines, some IoT vendors would make you think that’s all it takes. They can set up some alarms, alerts and flashing lights - and perhaps even send emails. From the surface, that may look interesting and bring some perceived value. The truth is, there is much more to it than simply aggregating data and when a threshold is hit, ringing the bell.
Machines on the production floor make items – that’s your life’s work and why you are in business. Each of these items have unique requirements in the production system. Perhaps it’s a tolerance, or an oven temperature something must be cured at. Perhaps it’s the punch press dwell time that’s critical – too quick and you get cracking, too slow and you get parts that are too weak to perform. Most times, production equipment will...Read More
In the past if you were labeled a clock-watcher that typically came with a negative connotation and would lead to a career limiting activity. You would have been the one that was just waiting for it to be 5-O’clock somewhere and you were just counting the minutes for the day and week to be over. In today’s business that activity of watching the clock may not be that bad, that is if you are doing it for the right reasons.
Business today has become much more time sensitive. No longer is a customer satisfied with a delivery date that is based on fixed lead times, they want it much more accurate as they are dependent . . .
Some of the biggest concerns with ERP Implementations are “will my people learn fast enough, will they retain what they need to know after the ERP Consultant has left, and will we lose core ERP knowledge if key people leave the company”.
If you are a multi-site manufacturing company and have implemented your ERP in at least one of your sites, but still have others on the implementation to-do list, one way to mitigate all of these concerns is to use an internal Mentor Program.
A Mentor Program is a concept of utilizing your previous investments . . .
Having accurate inventory is VERY important for the success of any ERP system. An accurate inventory will improve the efficiency of Customer Service, Purchasing, Manufacturing, and Shipping. Improving efficiency means reducing cost and waste in almost all of your processes.
We suggest that you measure inventory accuracy as part of your monthly “Dashboard”. This can be done by setting “accuracy standards” for your items. Not every item needs to be exactly correct in order to be “accurate”. For low cost, easily obtained items +/- 10% might be OK. For high cost, long lead time items, +/- 0% might be appropriate. They typical process for obtaining these numbers is through cycle count records, so if you are not already doing that, we highly recommend that you start.
First of all, there are two levels of inventory “accuracy” . . .
We are all called on to trim the fat and become more efficient. You understand the basics but putting thoughts/goals into action is all too often an overwhelming effort. But, an effort worth tackling.
In a recent training class with a number of quality professionals we were given a test assignment to simulate a manufacturing assembly process. We set up multiple work centers in our training room and took on multiple roles. Our team, which consisted of . . .Read More