Speaker: Michel Gadbois
It is popular to reference Murphy’s Law, which states that anything that can go wrong will go wrong. In the world of complex discrete manufacturing, Murphy’s Law takes shape as, “anything that can change, will change.”
You may conceive and work on a design for many months, fine-tuning as much as possible. Then it goes on a highly automated line to make a bushel of particular parts that are engineered in environments where things are constantly changing. You may process as many as 20,000 engineering changes per year and have to change your designs three times between your initial attempt to build the product and the time it actually leaves the door.
Before an aircraft carrier leaves the dry dock, it has been redesigned four times, taken apart, and put back together. Building something is a learning process. Technology is evolving. Sound familiar?
Without the right tool, it is impossible to control the need for manufacturing changes. Details slip through the cracks, mistakes are made but not discovered until the eleventh hour, and products must be torn down and rebuilt.
In complex discrete manufacturing, 30 percent of all mistakes are paperwork mistakes. It might not seem like a major undertaking to change the paperwork, but if you discover an incorrect serial number or a missing field, signature, or rubber stamp, you must assume the work was not completed or verified, or that an incorrect part number or no number at all has been assigned. The entire assembly must be torn down, re-inspected, rebuilt, and re-stamped.
Even though 30 percent of mistakes are related to paperwork, the cost of correcting them is 70 to 80 percent, which is equal to having drilled a hole through a part that should not have been drilled. Solumina puts variation into an environment where users can see it, control it, and make sure it progresses the intended way.
Complex discrete manufacturing takes time, but manufacturers can make sure that all of the interlocking changes, variations, and customer whims are accounted for in a structured environment that yields to a precise expectation at the end of every day. Visibility and control are critical.
At the end of the day, in order to compete in today’s digital manufacturing revolution, companies must find a solution to integrate all interfaces into one digital thread. Download our eBook to learn how Solumina software can make this a reality.