Speaker: Slavko Jovanovic
There are many reasons complex, discrete manufacturers struggle with shop floor efficiency. Typically, they have a point solution or silo solutions on the shop floor. These solutions are not integrated with the rest of their enterprise. Some companies still have no solution at all, and they are dealing with paper and manual systems. The reason for so much paper on the shop floor is because there are so many requirements. The requirements could be based around complex processes that require recording cure times for composites or how long the composites have been out of storage. There may be requirements to record run time rates for specialty equipment or burning times for other equipment. There are also many requirements associated with traceability for which paper or systems are typically used. Traceability must be projected into the supply chain, or the supplier must provide serialization of the parts that are coming in for raw material, certifications for the raw material and even the type of material they are providing. There are also other traceability or regulatory requirements associated with the Occupational Safety and Health Administration (OSHA) for safety and the International Organization for Standardization (ISO) for quality and corrective action.
The impact of the struggle for shop floor efficiency is a constant fear within the organization in terms of whether or not the operation is doing what it is supposed to do and the organization is building a safe, quality product in an efficient, profitable manner. Everything typically goes well until you put stress on such a system, and stress on a system can come from many different areas, such as meeting the customer deliverables. When that happens, there is worry about the paperwork being completed accurately. If change is introduced in the product, there is worry about the paperwork being changed correctly. For example, if a customer finds a product defect, there is worry about the paperwork accurately reflecting product delivery.
The best practice approach for increasing shop floor efficiency is to have an integrated electronic system. The system should not only take care of recording traceability information, and delivering product and process change to the shop floor, but it should also be proactive in assisting, identifying and solving problems before they occur.
An example of increasing shop floor efficiency would be to identify an out- of- control process by monitoring its output. Another example would be to tighten the sampling rules based on the number of defects found on the shop floor. To increase shop floor efficiency, sophisticated shop floor solutions are required.
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 can make this a reality.