by I2DS | Dec 7, 2023 | Blogs
Every Top Boss of every Organization of the world strives to make his/her organization the best in its class. If you read the Vision or Mission statement of any organization in the world this desire to be the best and even better, will become very evident. Irrespective of the line of business every company strives to be labeled the best in business, today we will talk about achieving this dream and making it a reality for manufacturing organizations, for whom their factories/plants are the main source of revenue.
To become the Best-In-Class operation, you need to realize that there is much more to the endeavor, than benchmarking the present best in the industry or otherwise. Benchmarking is very helpful but the main reasons for the success of the best organizations around the world can be attributed many factors, such as, strong leadership, clear vision, pro technology outlook, innovation, process control, quality ownership, zero error philosophy and above all 100% customer satisfaction. When the above mentioned features are embraced by the entire organization and these beliefs and practices enter the value system of each and every employee in the organization, becoming best-in-class is just a matter of time.
To develop such value system, integration of the entire process and involvement of employees along with ownership of process in critical. Information Solution like MES are providing process integration and automation for Organizations globally, which is helping them develop a more efficient, coherent and profitable operation. So what is an MES solution? Well, an MES application, as the name suggests helps better and more reliable execution of a manufacturing process, it gives higher degree of control over the process and facilitates real-time decision making. MES applications integrate every aspect of a production process and ascertain that no vital information is ever missed. Real-Time decision making happens when the MES keeps the process owners informed of every value adding activity at every step and ensures that tasks are performed as scheduled and are conforming to the perquisite standards. Such applications have proven to be extremely successful in controlling costs and increasing throughput.
There are many players in the MES space, that provide MES solutions, but who is the right partner for you? I2DS has the most revered automation and MES implementation team in the industry. Our experts specialize in MES, Factory Automation, PLC, APC, SPC, Data Tapping, Database Management and RFID Implementation. Our approach to automation is highly professional and customer centric. We believe that every process is unique and the level of automation required varies for each organization. Our experts provide automation solution that is not only leading edge but also highly efficient, there by assisting your team to make your process the Best-In-Class process in your industry. I2DS’ customers have experienced a higher throughput, better flexibility and greater profitability ever since they chose I2DS as their automation partner. Our goal is to provide process specific automation and manage the resultant change; this makes us a preferred partner in the industry today. So if you are in need of Leading Edge automation for your production plant, look no further, I2DS is here to assist you in this endeavor. For getting a better idea of how automation can improve your process and achieve a greater profitability, e-mail us right away at info@i2ds.com or just drop your inquiry in the comment box and we will get back to you
by I2DS | Dec 6, 2023 | Blogs
Quality has become the most sought after competitive priority to excel at, for organizations around the world. Consumers are willing to pay top dollar for products that claim to be of superior quality and can prove to be the quality leader in their category. There are nine facets of quality, 1) Aesthetics, 2) Conformance, 3) Durability, 4) Features, 5) Response, 6) Reliability, 7) Service, 8) Performance and 9) Reputation. Most of these facets depend on the process of production and to the extent the process can be controlled and modified. When a process can be controlled, its Quality can be improved as all possible causes of variances can be detected and successfully removed.
Customer satisfaction largely depends on the Quality of product, thus we can safely say that Quality management is vital for any organization that wishes to be competitive and achieve a higher market share. Quality control can be performed effectively when the vital process metrics can be measured and controlled effectively. To be able to make better use of the process metrics an SPC system or Statistical Process Control System is extremely useful. An SPC system becomes mandatory for products that have a complex process and face a high level of technological turbulence.
An SPC system if used should be process specific and be able to provide information that is highly refined and helps efficient and real time decision making. Nowadays there are systems that can perform complex calculations in fractions of seconds and provide valuable process specific information. However just any SPC application will not be able to benefit your Organization. An SPC system performs best when it is used with an MES application; this helps better Quality control and more transparency. So which application is required for your Organization and who are the guys you should use to implement it?
I2DS is the best choice, if you want the Best-In-Class SPC application at a reasonable price. At I2DS we realize the value a good SPC tool in your Organization’s system can add value to your entire operations and how it can improve your Quality control substantially. Our highly potent and capable SPC is capable of generating real time information like Cp & CpK Charts, Real-Time Process Data, Trends feedback, Tool Shutdown, Trend Charts, SMS Text Capabilities, E-mail alerts and other process specific charts and reports. Our SPC application is modeled as per your process and includes the metrics that you and your end customer consider vital. So if you have the desire to use Statistical tools to generate higher Quality, look no further, I2DS is right here to take care of Quality control endeavor. E-mail us at info@i2ds.com we welcome your comments and suggestions as well, please leave a comment if you find the content useful or just want to know more about our products.
by I2DS | Dec 5, 2023 | Blogs
Mura, Muri and Muda are the three types of wastes we see in Japanese management theories. Mura corresponds to unevenness in production, Muri is overburdening the workers and production process and Muda is non value adding work which attributes to waste. We often forget the importance of detecting the defects that cause these wastes. Finding the root cause of a particular waste type may prove helpful in eliminating the waste from the process, or at least lead to a considerable reduction in the waste being produced. All three wastes mentioned above can be witnessed in any typical manufacturing operation; these wastes are the major cause of loss of productivity and process down time.
Even in preventive maintenance programs the stress is laid on trying to increase the machine uptime and the final product remains neglected to an extent. In order to reach the desired standard of compliance and reduce the waste being generated it is imperative to analyze the defects being encountered during the production and try and detect the root cause for them. Defect management practices not only ensure steady production but also boost quality and reduce down time.
To effectively manage and control defects a Defect Management System should be employed, either individually or as a part of a bigger integrated application such as an MES. The better way of implementing the defect management system is having it integrated in the MES itself to give a better result due to the integrated nature of the application. This way the entire production process remains transparent and it becomes easier to identify the defect and its root cause. MES applications today have become advanced and can accommodate such applications as defect management. But the question that remains important is, which MES product is suitable for your process?
Well, the answer is quite simple; the best partner for your MES implementation and defect management is I2DS. Let me explain why, I2DS is one of the few companies in the industry that has a team of experts in Operations Management, it has developed the most sought MES application and they are the leaders in design and implementation of Defect Management Systems. These inherent qualities of I2DS make it one of the most sought after solution provider in the Manufacturing Automation industry. However actions speak louder than words and we would want you to see how effective our systems are and then make your choice. So if you are struggling with defect management and want a company that can understand your process, get in touch right away and make your production more productive. Our e-mail is info@i2ds.com, you can also leave your query in the comment box and we will get back to you.
by I2DS | Dec 4, 2023 | Blogs
Is your factory operation the best-in-class in your industry? Is it operating at optimum efficiency/effectiveness? Are the operational efforts well-coordinated, well communicated and well documented? Do you have the ability to monitor each and every activity in real-time and make profitable decisions? Today these are the questions that are critical for an Organization that believes in achieving the highest possible Quality at the lowest possible cost. Manufacturing organizations today are constantly under pressure to develop newer, better products much faster than ever before. This means that the factory operation needs to be achieving optimum efficiency just to be able to cater to the needs of the dynamic conditions and highly demanding markets.
Organizations that can boast of having the best-in-class operations in the industry have been able to do so by strategic planning and employing/developing path breaking technologies. For manufacturing Organizations, it is extremely vital to have a synchronized and integrated operation, which works together as a single unit. Understanding the importance of Technology and the role it plays in the success of the best organizations can help us understand how technology can contribute towards making our operation the best-in-class operation. One of the most important facets of technology is IT or Information Technology. IT is being used to integrate operations, provide better customer service, facilitate decision making and increase throughput of the entire Organization.
The need of the hour is to have information solutions that enable you to better adjust with the market forces and still be able to achieve optimum efficiency, so that profits of the firm are not affected. I2DS has been able to provide powerful Information solutions to its customers and helped them achieve the efficiency that they desire. We believe that only on integrating the Factory Operations can an organization get a handle on what’s going on in their factory and how to better control and synchronize the efforts. Our solutions give you a better picture of every activity that happens on the floor and generate real-time reports that enable effective decision making.
Our path breaking MES product gives you a common platform for all your operations, this enables integration and real time decision making. Every lot that is run can be configured from the beginning to EOL; right from selecting lot-path to lot-recipe, each lot can be tracked irrespective of current location. EDC and SPC features allow better control and quality; they also enable real-time analysis and help better and faster implementation of corrective action plans. It helps generate reports that are available for analysis as and when required. All in all our MES solution gives you the functionality of optimizing and integrating your operations right from planning to execution, in real-time.
But the benefits that I2DS can provide to your factory ops don’t stop here, we have made it our mission to go beyond the realm of basic MES and our Manufacturing Excellence Solution does exactly that. I2DS’ Manufacturing Excellence allows you to monitor all the major issues on your factory floor which include, Quality, Safety, Equipment Issues & Communication Management. This solution helps you gauge issues besides regular factory operations which are just as critical as the operations itself. Each and every issue that is related to Quality, Safety & Equipment becomes very important as neglecting them can lead to high and unwanted cost implications. Our Manufacturing Excellence solution allows you to report, track and analyze all these vital issues and make real-time decisions.
Equipped with these powerful tools you can achieve a highly robust, integrated and optimally efficient operation. I2DS’ endeavor is to help customers achieve operational excellence has lead us to develop even more amazing solutions right from Database Management to a complete IT outsourcing partner. So if you want to feel the happiness that results from a factory that is working at its true potential write into us at info@i2ds.com.
by I2DS | Nov 29, 2023 | Blogs
By Vivek Bhachawat
Is Safety the first priority in your Organization? Is worker safety and a hazard free working environment really what you strive for? It is seen that many organizations have fancy policies and documents portraying the concern they have for the safety of their workforce, but the reality is very different. These protocols and procedures that organizations claim to have in place are generally to achieve documentary compliance for various certifications and audits, with the end-goal remaining a boost in profits. Safety, however remain neglected and procedures become a joke if they are not practiced as is, any leeway that occurs in safety procedures no matter how trivial, can prove to be very costly. If we look at tragedy’s that have previously occurred, such as the Oil spill in the Pacific, Gas Tragedy in India and nuclear blast in Russia, all of them could have been avoided if safety policies and procedures were robust and well adhered to.
Even in organizations which do not pose an overt threat to workers or the environment, safety is the most basic and primary need for any individual and the duty of the management of any organization to fulfill this need is implied. As per Abraham Maslow’s theory about ‘Hierarchy of needs’, Safety, at the workplace is then first and foremost need of any worker. So when we say Safety First, we should mean it and work towards achieving it, because no one would like to work in an unsafe working environment. The life of a person is of the highest value and to ensure the safety of workers the highest responsibility of any organization. Many management practices like Poka Yoke widely practiced in Japan aims to fool-proof a given process in terms of operations in lean manufacturing, but similar processes can be used in Safety from a Safety Management point of view. The trick is to make a safety procedure both effective and efficient at the same time and this can be done using IT.
Today there are various industrial safety standards around the world that are helping Organizations better understand and develop safety related policies and procedures, OSHA Act 1970 USA- Occupational Safety and Health Administration Act, is one such example, where a clearly defined set of rules have to be adhered to for Safety and Health. Almost every country has similar rules for the minimum safety requirements for industrial establishments. Companies around the world need to better monitor and achieve these safety standards, but the problem that they face is that the efforts made for safety management are not fully integrated, there is a need for a system that would provide a greater insight on what is happening and what needs to be done for safety across the entire Organization.
The need is to truly believe in the Mantra- ‘Safety First.’, and practice it through IT solutions. Today there are many products in the market which are helping organizations streamline their Safety efforts and thereby achieve a cost effective yet robust management, to ensure a safe working environment. Automated systems today are capable of providing features ranging from risk-assessment to providing safety training. With a right IT application the possibilities become limitless. But, it is very important to understand your own needs first before jumping for a solution. You need to first understand the industry practices for safety, then compare them with your current system and establish what needs to be automated and why. Then you need to work with a competent vendor, who understands your industry’s requirement and can achieve the safety level you desire, with minimum efforts and cost. So if you really want a Safe working environment, you need to think safety, plan for safety and act for safety, but with an IT perspective to make a fool-proof, robust and cost-effective safety solution.
by I2DS | Nov 27, 2023 | Blogs
Process control, is a derivative of the school of thought that believes that management should be treated as more of a Science and should be based on hardcore evidence and facts, rather than managerial whims. I am an ardent believer of the same truly believe that what can be measured can definitely be managed when it comes to a process that has certain parameters and metrics. However, I do believe that when is comes to leading a team or converting a sales call a certain degree of personal charisma is required and that is a bit of an art, but when we talk about managing a process it is a pure science and should be subjected to strict and clearly defined process control measures.
All modern theories of management such as TQM, Lean, Six Sigma and others state the importance of SPC or Statistical Process Control in process management. SPC enables accurate process control and ensures quality parameters are achieved. SPC can be applied universally to any process where the required output can be measured. Some key tools used in SPC include control charts; a focus on continuous improvement; and the design of experiments. In simpler words SPC is a tool for Quality control that aims to achieve following objectives 1) Objective analysis of any variation 2) Increasing Productivity 3) Early detection of quality and performance related issues. If applied properly SPC can provide your Organization the competitive edge it requires.
If your factory requires better process control you need to consider the possibility of applying an SPC application that has the capability to collect, measure and analyze all process metrics and provide the desired information to facilitate better decision making. The ideal scenario is when your MES application has an in-built feature that incorporates an SPC. However most MES systems lack the effective implementation of SPC and that’s where I2DS comes in the picture. We have been able to incorporate one of the most revered SPC modules in our MES application, thereby providing our clients a seamless integration of their process functioning and process control.
We as an Organization truly believe that to achieve six sigma levels of production an effective SPC is mandatory. We specialize in the design and application of industry and process specific SPC applications. You can choose to apply our SPC separately or along with our MES application, we always recommend that SPC be employed with an MES for better functionality. If you need an SPC application and would like to understand how employing it can aid better process control, faster decision making, better quality and higher profitability, then you need to see our SPC application in action. To know more about SPC applications for your industry, e-mail us right away at info@i2ds.com or just hit the Request Live Demo Tab on this webpage.
