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Why is it not reasonable to connect machines at the production hall to the manufacturing control system and production tracking software in small businesses?

Why is it not reasonable to connect machines at the production hall to the manufacturing control system and production tracking software in small businesses?

You have been using your manufacturing control system for a while, and you have enjoyed the benefits of production tracking software. But the truth is: the more you have, the more you want. Many of our clients asked the same question: what’s next? Shall we connect machines to a manufacturing control system to track production even further? For 99% of small companies, it is not a good idea. Let us explain why.

1. Usually, most companies have a diverse infrastructure, which results in significant difficulties with adapting their hardware.

Even when there are many state-of-the-art machines in your workshop, they probably don’t come from the same producer, and they weren’t bought at the same time. What is specific to a small business: new equipment purchased once the company develops, in random order, some of it being second hand, etc. 

Therefore, it is challenging to adjust transmitters to the same standard of data collection, as different producers use various systems (including Bluetooth technology, wifi, cable). At times a specialist company has to be hired to get things working, which of course doesn’t come cheap.

program do zarządzania produkcją maszyny

2. This kind of system breeds technical problems, which misses the point, as the solution should be failure-proof. 

The best example is a wi-fi situation at a particular production hall. It is often challenging to get a simple Wi-Fi Internet connection to set up a computer with Prodio and register production. We talk here about the most straightforward thing, such as using a browser, logging into your online account to use manufacturing control software. It’s not just the case of the signal or poor reception. Other factors include electromagnetic interference generated by CNC machines, power surge, moving forklifts, breaks in power supply, machine restarts, etc. Imagine that you have plugged your CNC machines with different types of transmitters with various ranges of signals in these circumstances, which use wi-fi/Bluetooth to send data to a base station. Then take into account the number of interference and changing factors discussed above. Nobody wants to use cables to connect things or send data (it would mean lots of tangled wires on the shop floor). 

The base station has to collect data in the INTEGRAL way (it is enough when it fails to receive only one signal about the start/the end of the operation and things go awry). It would mean that all data has to be re-sent from this application to MES /other manufacturing control system.


3. There are many typically manual processes, and they are usually the most important but can’t be included in such a manufacturing control system.

Years of experience working with different companies and our clients’ stories show that manufacturing control software / MES such as Prodio is the most impressive when operations aren’t fully automated. It is not important whether we talk about manual glueing of cardboard boxes, carpentry jobs, milling machine operators or technologers. It is typical for the small manufacturing companies that they don’t have long automated assembly lines but rather flexible solutions, making them competitive. When the machines enable easy connection to different readers or transmitters, it usually means that they are automated, sophisticated and self-sustainable devices. Efficiency tracking in a system makes no sense, as these machines work all the time, regardless of their operator (it is often one person who checks a few devices). Therefore it doesn’t matter how productively the operators work because the machine’s efficiency is known at creating production technology. 

manufacturing control system warehouse

The question is whether it is worth investing large amounts if still won’t be able to measure the time of manual operations, simple numerical machine tools and a whole bunch of activities where it is not possible to connect some reader measuring their efficiency when all you want is better control and improvement. 

manufacturing control system
Illustration 1 – Try to connect the computer 🙂

 

4. It would be hard to avoid clicking in your MES/production management and manufacturing control system.

Another motivation to connect machines to the manufacturing control system is the idea that an employee won’t have to click anything on the computer at the production hall. However, you still want to know what is happening and how productive people are. To avoid all this clicking, you need to have this information in the machines, and it would still require using MES (in large manufacturing companies, this is how it’s organised, that on the global level, it is clear what each machine is doing).

To sum things up:

Of course, it is up to you – it is not impossible, it’s just the case of time and money. The question is whether this kind of investment would be worth your stress and financial input.

It takes less than 1 hour to implement manufacturing control software such as Prodio, and it costs from 97 dollars per month. The software pays off from day one because it makes you ten times as much money, if not more, improving your manufacturing company’s overall profitability and giving you back free time and peace of mind. 

Once you decide to connect machines to the Internet, the calculation might not be that simple. The investment may take years to pay off, and in the worst-case scenario – it will never pay off because sooner you will give up on the whole experiment. 

Why would you give up? Because the system should work failure-proof and trustworthy. The number of variables and possible different problems with connecting machines to the network, data transfer, etc., could make it fallible. Consequently, people would stop trusting the system or still use different control methods, such as paper notebooks. After all, this is not the result you desired to achieve.  

Grab an mp3 to listen about connecting machines to manufacturing control system.


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plan produkcji

Kaikaku method

Kaikaku method

Kaikaku method – how does it work?

Kaikaku method

Today’s business environment is characterized by strong global competition and fast-paced changes. That’s why production functions of manufacturing companies must have a capacity of undertaking large-scale improvement of a radial and innovative nature.
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Kaikaku definition

Kaikaku is a Japanese word meaning change or reformation. The Kaikaku method tends to entail large-scale changes involving wide ranging activities. Changes are made in, for instance, production processes, pieces of production equipment, culture in organizations, manufacturing strategies, leadership styles, information systems, and management processes. In some cases, the scope of the change was not only the production systems but also all production functions or the whole company. It often involved implementation of lean production. 

Nowadays companies must be proficient in radical innovation in production to maintain their advantages. They must be capable of creating new knowledge and constantly developing and implementing new production technologies, processes, and equipment which helps them to keep competitive edge and make “unique” goods. Kaikaku offers improvement that involves fundamental rethinking and radical design of systems and processes related to production, performance of the production system which is frequently measured in terms of cost, quality, speed, and flexibility. 

Kaikaku implementation

Kaikaku is a deliberate effort initiated by top and senior management and requires a strong direction from the management, as the implementation and the result significantly impact business. Since Kaikaku often changes the processes that involve different groups, divisions, or departments in the organizations, coordination and direction from the high-level management are needed. The Kaikaku method can be characterized as a top-down approach, but this does not necessarily mean that changes are never collaborative and participative. Sometimes the actual changes are driven by employees at lower levels of the organization. 

Kaikaku form

Kaikaku uses a definite time period with specific targets to be achieved at the end of the period. Therefore, it is typically seen as a large project or an initiative. The large project often contains smaller ones conducted at different points of time during the overall initiative. The time frames of the Kaikaku initiatives ranged from a few months to a few years. 

Kaikaku process

The Kaikaku process consists of several stages:

  1. Preparation

It is important here to ensure management commitment, identify necessary changes,  set up strategy and targets, prepare smaller projects and allocate tasks, together with educating staff on further steps.

  1. Redesign 

This phase allows us to analyse processes and make necessary adjustments as well as  test and evaluate solutions.

  1. Implementation

Finally it’s time to implement new systems and processes, provide training for employees  and monitor changes. 

Kaikaku projects

Kaikaku projects can be of four different types:

  • Locally innovative implementation – for example introducing a solution well-known to the industry, but new to the company;
  • Locally innovative methodology – for example introducing new methods, well-known to the industry, but new to the company;
  • Globally innovative implementation – for example introducing a new solution to the industry;
  • Globally innovative methodology – for example introducing a new production theory to the industry.

Some of the Kaikaku projects result in improvements in the range of 30-50% due to their radicality.

Organization structures and resources need to be prepared to support the mentioned types of Kaikaku. A process of Kaikaku can be seen as a series of unfolding smaller improvements or development projects that are undertaken to achieve overall objectives. In each project exploration and organizational learning are facilitated, so even in a smaller company it is possible to benefit from such an approach.

If you wish to learn more about other methods of optimization of production planning processes check out this article.

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One Piece Flow method

One Piece Flow method

How does One Piece Flow work?

One piece flow is the basis of lean philosophy. In short, one piece flow is the opposite of batch production. In this system, the time when the product is not worked on/processed is minimized. Read on to find out more.

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One Piece Flow method

One Piece Flow method, sometimes called continuous flow, is a production method used instead of traditional mass production. In mass production, materials move through the manufacturing process in batches which can be highly inefficient. In one-piece flow, a product is completed before the next one is started. The name refers to a maximum number of products between operations, workstations, processes. That’s why it’s also called “single piece flow”, as everything is constantly progressing and only one item is in any given queue at a time. Multiple items can be in the process as a whole, but nothing has to queue up and take up space from the moment it starts until the moment it’s complete. Thanks to One Piece Flow you can save time and money, as work is performed faster and any space you use is highly optimized. The customer also receives ordered goods much faster than in a batch method. This reduces waste (you’re not spending money holding items for future delivery) but requires a huge amount of coordination and consistency to pull off.

One Piece Flow – the beginning 

The beginnings of the One Piece Flow are in 1934, when Kiichiro Toyoda used this method at a foundry and engine production. He used a concept of “confirming one, after the other”, which aimed at saving time and eliminating mistakes as they were spotted mid-batch before  affecting the entire order. Two main advantages of One Piece Flow were noticed: that work is completed faster and the money is saved both due to the time and space you free up. That said, these simple benefits have huge knock-on effects. The One Piece Flow method can be implemented almost anywhere providing the operations and processes are repetitive. Other necessary requirements include:

  1. The number of workstations has to be bigger than one. 
  2. Make sure that the flow of work is clearly visible, tracked and standardized by using a production planning system.
  3. The workstations should be balanced, which means that time spent at each of them should be similar.

What is a production cell?

The term “production cell” is very important for the One Piece Flow method. It refers to workstations and machines which are set up next to each other, which ensure the production flow is smooth and the product can follow easily all production stages. Modern work cell allows for the implementation of the entire production process as a one-piece flow, thus eliminating any waste and ensuring the highest quality of the end product.

One Piece Flow – the  benefits of implementation 

There are a few major benefits of One Piece Flow:

  • Improved quality

First up, using One Piece Flow can make your final results higher quality than if you tackled them in bulk. This is because errors are more likely to be spotted partway through the process than at the very end when it’s too late to correct them. With One Piece Flow, the problem is detected at its first occurrence, thus we will not produce next defective parts.

  • Less elements in the process  

It is easier to scale up your operations and do so reliably, since you can monitor the production of each product across every step of the process. When you control the production plan we no longer have to monitor and change the plan for numerous stations, but only for a select one. Additionally, by breaking up your process into set workstations and blocks of tasks you can more easily see where you can benefit from using business process automation. Any initial cost of setting up the automation would quickly be offset by both the money you save with one piece flow and with the savings your new automation will make 

  • Smaller production hall

We do not need so much space to store products between operations. Workstations can be situated closer to each other, and a smaller hall means not only smaller rent, but also less space that needs heating, cleaning, lighting, etc. Production cells are located next to each other to offer smooth transition between operations.

  •  Flexibility and productivity

In the one piece flow system you can immediately see which process is faster, so that we could respond more easily. For example, evenly distribute work between stations. This enables us to identify bottlenecks and  use resources optimally. We do not see this in batch production. 

  • Faster response to customer’s order

Refitting the line for other products or orders is much easier. We don’t have to take away containers, crates, pallets from various processes and supply new ones. The operator / machine simply adjusts itself to another product. That’s why the customer will get their order faster as they don’t have to wait until all ordered items are cut, milled, painted and assembled. This process often takes days, weeks or months. The faster the product is available to the client, the faster we can invoice. What’s more your processes will be more flexible to the customer. Since you’re able to fulfill orders and tasks much faster, you can leave them for longer before starting work on them. This then leaves more time for the customer to make any alterations before you’ve already started work.

  • Better ergonomy 

Workstations are optimized for the implementation of the One Piece Flow method.

  • Increase the morale of your workforce

Depending on how your process is set up, continuous flow can also help to increase the morale of your workforce. As long as there is still some variation in duties (eg, switching employee tasks every so often) the higher rate of progress can help to show your employees that the work they’re doing is making something worthwhile.

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How does JIT system work?

How does JIT system work?

How does JIT system work?

Just-in-time (JIT) method

There are many different methods of optimization, which are part of lean management. Read on to learn about one of them.

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What is the Just-in-Time Method?

The Just in Time (JIT) style of inventory management – also sometimes referred to as the Toyota Production System (TPS) – is a strategy of managing inventory and/or production that links the ordering of raw materials to production scheduling. 

Kiichirō Toyoda is considered to be the “father” of this concept, which was firstly implemented in Toyota from the 1950s to 1962. JIT method has roots in Japanese culture  – geographic location of the country is determined by about 4 000 islands constituting the archipelago, so naturally Japanese prefered management style based on creating goods directly related to the orders being placed, instead of making extra goods to meet the needs of any potential orders that may be placed. The JIT method ultimately helps companies cut down on waste from making too many products (or supplying too many goods). Therefore, they don’t use up raw materials that may or may not actually be necessary to fulfill the orders they have. In turn, it cuts down on the costs they have for inventory, freeing up cash flow.

System JIT revolutionized approach to sales and production. Most companies create and hold inventory in excess, meaning they create goods in anticipation of other orders. The Just in Time method involves creating, storing, and keeping track of only enough orders to supply the actual demand for the company‘s products.

JIT model is based on the idea that clients should get: 

  • Suitable product / service
  • Specified quantity
  • in Agreed time frame

JIT implementation tips 

It is highly recommended to run a series of different analyses before implementing the JIT model, which will help you to go through the whole process smoothly. To fully benefit from the JIT method the company should:

  • Invest in analytical technologies, which will enable successful demand and supply forecasting;
  • Make short production runs, which means that it has to quickly move from one product to another. Furthermore, the company should reduce costs by minimizing warehouse needs.
  • Improve the flow of information (it should be smooth and without any communication breakdowns; the cooperation between suppliers, producers and end clients is key to achieve success);
  • Eliminate potential disruptions in the supply chain. If a raw materials supplier has a breakdown and cannot deliver the goods in a timely manner, this could conceivably stall the entire production process. A sudden unexpected order for goods may delay the delivery of finished products to end clients. (The company should choose a right supplier and the pricing cannot by one of the most important criteria giving field to reliability and efficiency);
  • Eliminate unnecessary processes ex. in the machine changeover procedure and improve the speed of maintenance tasks.  

Not every supplier or manufacturer has the luxury of ordering only the materials they need to complete a specific order. A company must consider potential variables in the manufacturing process – such as inclement weather delaying receipt of inventory materials, labor strikes or supply shortages – before deciding if this inventory method is right for their organization. JIT cannot be implemented unless a company has high production, steady production, high quality output and stable suppliers. Otherwise there is always a danger of using up all supplies and complaints from the customers, because of delays, as timing was determined by prior orders and supply history.

The JIT method is advantageous to companies because of the reduction of waste it offers. The system highlights problem areas by measuring lead and cycle times across the production process, which helps identify upper limits for work-in-process inventory, in order to avoid overcapacity. The JIT production method cuts inventory costs because manufacturers do not have to pay storage costs. Manufacturers are also not left with unwanted inventory if an order is canceled or not fulfilled. 

One of the essential steps in the JIT implementation process is introduction of the pull system. In contrast with the push approach, which is a synonym of passing on different goods from one workstation to the next until the final product leaves the production hall, JIT inventory method is considered a “pull” approach in manufacturing. When sales activities warrant more production, inventory is “pulled” and more manufacturing supplies are ordered. Separate workstations are treated as independent in company “clients”. In the “pull” system they are responsible for signaling demand for products and instigating the whole production process. It results in a smooth flow of production and reduced inventory costs. This method relies on signals given at different points in the production process that tell the manufacturer when to make the next part.

What are the advantages of the JIT method?

One major advantage of the just-in-time inventory management system is that funds that were tied up in inventory costs can be used elsewhere. Likewise, areas devoted to storing inventory are now free to be used in production or for other needs within the company. Other advantages include:

  • Less waste and lower inventory costs, which result in increased profits for the organization;
  • Better information flow, supply tracking, goods distribution;
  • Employees skills are better utilized (multitasking, multi skilling);
  • Production planning is synchronized with demand –  when there is no demand for goods, they aren’t produced. It creates savings and better cash flow; inventory is reduced even by 30%;
  • Utilizing the raw materials in a timely way so as to fill orders on a timely basis (the risk of goods being damaged or out of date is minimized);
  • Suppliers get the raw materials to the company in a timely way, which results in an improved relationship. Potential conflicts are cleared straight away;
  • A company efficiently using raw materials, leaving little to no raw materials left over after production;
  • Possibility of committing to more orders;
  • Shorten time of order delivery and completion.

 

Take a shortcut and start planning your production online.

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MS EXCEL for production analyses and calculation (ready spreadsheet for advanced calculation of working history)

MS EXCEL for production analyses and calculation (ready spreadsheet for advanced calculation of working history)

MS EXCEL analysis and production calculation (download ready to use spreadsheet).

This year a “bunny rabbit” got you a special Easter treat in a form of calculation spreadsheet, thanks to which data collected with PRODIO, will help you to reach conclusions and make better decisions.

MS EXCEL analyses and calculation of production – why use a spreadsheet not Prodio ?

Prodio allows you to check (and probably some of the users even don’t know it) the real cost of labour of each detail (resulting from the cost of man-hours), compare planned time with lead time, sum things up using filters, compare any given data in hundreds of ways and many more…

Each of the tens of companies that use Prodio, analyse data in a unique way—  that’s why while creating the software we wanted to give the opportunity to export information to Excel in an easy way.

MS Excel spreadsheets were created to analyse data — giving great possibilities to visualize and accounting, so contrary to registration and managing production, using spreadsheets for calculating makes more sense.

You don’t have to be an “Excel mastermind” because to make data analysis easier (which can be a very lengthy and complicated process) we prepared some ready files (like this one), even when you are familiar with only basic Excel function thanks to them you will be able to handle quite sophisticated calculations.

 

 

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IMPORTANT ANNOUNCEMENTS REGARDING PRODUCTION ANALYSE IN MS EXCEL

1.OUR TARGET IS TO MOVE MAJORITY OF ANALYSES TO PRODIO, SO LET US KNOW WHICH ANALYSES SHOULD BE DIRECTLY IN THE SYSTEM.

Apart from helping you, we would like to use the present form of spreadsheet to collect opinions and ideas, which reports should go to Prodio itself.

This is very important for us to have your insight on how it should look. If any comments repeat we will try to implement them. So far we considered adding many new parameters (including OEE, shifts division or machines occupancy forecast).

2. THE SPREADSHEET IS UPDATED CONSTANTLY

The current spreadsheet is a tested and developing version, so it can contain some mistakes / or some elements that might be missing. We will make it better and work on real-time updates on receiving your comments – the newest version can be found when you click on the link below  

3. Equipment requirements

We intentionally used MS Office 2007 to create a spreadsheet (this is the oldest version possible to use) –  and to assure compatibility with older versions of spreadsheets. To make analyses an older computer model is also sufficient.

Analyse and production calculation in MS Excel

Available analyses:

1. Machine and operation – graph:

A single machine/operation occupation history (with efficiency and graphs).

    Analiza obłożenia i wydajności maszyny MS Excel

In this bookmark you can learn:

  •  how much worked a SINGLE machine/operation weekly/monthly (ex. to check occupancy and see if all working stations are used well)
  •  how long would it take if the machine/operation was doing the same job, but accordingly to norms set in products technology  (to see which machines/operations are the weakest or underestimated in your technological processes)
  • compare in percentages planned times with lead times from the point of the improvement process. 

2. Machines and operations occupancy

The total summary of all machines/operations occupancy.

Maszyny łaczne oblozenia - analiza

In this bookmark you can learn how to:

  • easily sum and compare how much worked machines /operations in a particular month (ex. to check occupancy and see if all working stations are used well);
  • easily sum and compare how much worked machines /operations in a particular week (ex. to check occupancy and see if all working stations are used well);
  • this summary is used mainly to see whether there are any discrepancies in particular processes

 3. Employee’s efficiency:

Work occupational history for the particular employee (with efficiency and graphs).

Analiza pracownika MS ExcelIn this bookmark you can learn:

  • how much an employee worked monthly / weekly
  • how long would it take if an employee was doing the same job, but accordingly to norms set in products technology  (to see which employees  are the weakest);
  • compare in percentages planned times with lead times from the point of the improvement process.

4. EXTERNAL CALCULATIONS, ORDERS: 

A comprehensive analyses of multi-position orders (by external order number), very useful, when you need quickly summarize a whole ex. 20 position order, without dividing it into single items. 

In this bookmark you can learn:

  • how long it took, in total, to complete the whole (multi-position) order
  • what was the total time conditioned by the production technology and norms
  • compare planned timed with lead times
  • see which machines/operations had  the biggest discrepancies
  • see which employees contributed the most to appearing of those discrepancies while completing the order
  • how many pieces were completed and how many shortages were in the process

5.PRODUCT ANALYSES:
A comprehensive analyses of production for a given assortment regarding the whole product making – the best knowledge compendium on your products.

Analiza i rozlczenie produkcji produktu MS Excel

In this bookmark you can learn:

  • how long on average it takes to make a product by particular machines/operations;
  • which operations are underestimated, and which can cut from the calculations;
  • compare planned times and lead times for each product;
  • which processes generate the most shortages
  • which employees are the best at completing a given product (in total);
  • how efficiently particular employees work on given product/operation;
  • how many pieces were made and when (in which months) the production was the biggest;

How to use it – Spreadsheet preparation:

  1. Download and open an updated version of the spreadsheet by clicking here
  2. Go to a bookmark Working history in Prodio, then click „Export the history of operations”.Data analyses
  3. Open the downloaded file with a working history, mark columns A to T and press “Copy”.
  4. In the analyses file go to bookmark “Pasting”, position mouse in A1 cell and then click “Paste”. The software will ask if you want to change content, to which we mark “YES”, as an answer.
  5. It’s ready 🙂

 

Update 1.08.2019 🙂

A BONUS: WORKING TIME AND WORK CHECK INS / CHECK OUTS ANALYSES SPEADSHEET.

We added the present file to analyses and calculation of working time (RCP) based on Prodio’s data, where there are among others 

  • working time division on Saturdays, Sundays and weekdays 
  • overtime and basic working time division
  • clear list of working hours by days 

Click (HERE) to download or click the graphic below:

Rozliczenie czasu pracy (RCP) Ms Excel plik

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