by I2DS | Nov 15, 2022 | Blogs
Factories have transformed drastically in the last 100 years or so, the main reason behind this is the advancement in Process Technology and the revolution called Information Technology. Yes, long gone are the days when every production step was executed manually and the entire process was subject to a myriad of non-conformities and issues. Today the standards for production have become stringent and some details are impossible to achieve without having a total or partial automation. Factories of tomorrow are the ones that realize this need for automation and work towards becoming more advanced using better process and information technology. The organizations that have reached high level of proficiency give the credit to better technology.
But wait, what is better technology and does automation mean the elimination of human work force entirely? Well, automation can be considered as a continuum against human intervention, the lower the amount of human intervention in the actual production process the more automated the process. However, automation does not mean elimination of the human workforce entirely, let me explain. Even though a plant may be fully automated in terms of machinery, in the entire production process humans play the role of interfaces between operations, even if the entire production process is executed continuously, the need for humans still remains to monitor and manipulate the process as desired/required.
The level of automation in general is rising in all industries; the major reason for this is the proliferation of IT solutions that are integrating processes, even those that are geographically at separate locations. Even in industries that have saturated themselves in terms of process technology, IT is helping them reduce costs and improve process efficiency and net profitability. Market leaders have embraced IT and consider it the most important facet of automation. It is through applications like PLC, SCADA, HMI, SPC and MES that the modern factories become automated in the true sense of the word.
Information Technology is the Present and Future of Factory Automation and the future is here and now. Yes, you have the power to make your factory a fully automated, technology driven and highly profitable entity, all you need to do is understand the role of Information Technology in your process and apply it. To achieve the best results in factory automation you need to work with experts, who know what is factory automation and what scope does IT have in your production process. To know more about Factory Automation or understand the need for it, please get in touch with us right away at info@i2ds.com.
by I2DS | Nov 14, 2022 | Blogs
MES applications are transforming the way production units operate, they are making factories more integrated, efficient and quality oriented. MES applications are basically software solutions that have the capability to provide seamless integration for a manufacturing facility, right from warehouse to the EOL or end of production line. An MES app helps you manage production in real-time and prevent formation of bottle-necks, monitor and control your process and above all improve the overall efficiency of production. The major advantage of having an MES app is the clarity you have about your process and how fast and accurate decision making becomes. The major contribution that such an app provides is towards the Quality of the end-product. An MES app can help you monitor every aspect of product quality and ensure that the end-product is compliant and perfect.
The heart of an MES app is an SPC tool, it is through this SPC tool that real-time data analysis and decision making is possible. An SPC application allows to enter and analyze all process and product related metrics. Such a tool can lead to not only 100% compliance but also help improve quality by removing assignable causes of errors. Companies that aim for a Six Sigma level process or the ones aiming to achieve Lean management in the true sense can hugely benefit from an SPC system embedded in their MES application. This saves not only cost but precious time that is otherwise wasted doing complex calculation, which is subject to human error or calculation error if performed manually. An SPC application also provides visual tools that help understand the Data better and achieve better process control. I believe an MES application is incomplete without an SPC application.
So the real question here is, how important is SPC in your Organization? Is your SPC application capable of delivering high class and potent decision making info? Do you need a better SPC application, embedded in your MES app? These questions are extremely critical if you are a manufacturing Organization that has highly complex processes and high quality standards for your final products. SPC application today requires being highly efficient and delivering much more than just basic trend charts. If your SPC application is delivering just Trend Charts you are not fully utilizing the power an SPC application can truly provide. A truly potent and capable SPC should be capable of applications like CpK Charts, Real-Time Process Data, Trends feedback, Tool Shutdown, SMS Text Capabilities, E-mail alerts and other process specific charts and reports.
At I2DS we realize the value a good SPC tool in your Organization’s system can add value to your entire operations. Our SPC solution is integrated in our MES system and it allows the above mentioned functionalities in real time. This makes your control function extremely powerful as you can monitor SPC data in real time and make decisions simultaneously, that too without having to use any other system/tool for analysis. Our SPC might appear magical to a common man but it’s a powerful tool for a manager who deals with issues like quality and cost of production. I2DS’ SPC has the capability to integrate and compare the process data from multiple factories of the Organization, providing you a comprehensive analysis tool. Our SPC is the perfect Quality and Equipment ‘Doctor’, because it helps you diagnose and cure every issue pertaining to them. The reports that our SPC generates helps you get a 360 degree view of the entire operation and this helps you make more accurate and profitable decisions. So for a live demo e-mail us at info@i2ds.com or request a Live Demo on this web page.
by I2DS | Nov 8, 2022 | Blogs
Discreet Manufacturing is considered different from process manufacturing because the end product being produced is different every time, unlike process manufacturing. Practices like customization and delayed differentiation have allowed discreet manufacturers achieve the economies of scale and scope. Process manufacturing concentrates on refining the process and achieving the same end result every time with lesser cost and higher quality. In discreet manufacturing however, the process of production needs to be flexible and adapt itself to the desired end result. In discreet manufacturing the ability of the process to change as the product specifications change is a prerogative, also the high standards for quality and the pressure to lower the cost is ever existent.
MES applications for process manufacturing generally concentrate on the integration of the operation and achieving higher quality by achieving better process control and facilitating real-time decision making. The requirement of flexibility is not as important in MES applications for process manufacturing. In discreet manufacturing however, flexibility is the top priority. Coming back to the topic of today’s blog, Is an MES application successful in discreet manufacturing? The answer is No and Yes. The reason I have given such an answer is not to confuse my readers but to state the following observation. In my experience an MES application can fail any where irrespective of the production process, this happens because the management fails to determine their needs and choose the wrong application. In such a case an MES application might fail in a discreet process as well. For an MES application to be successful the management needs to carefully assess their needs and choose an MES application accordingly.
I believe that every process is unique and should be considered individually, especially for discreet manufacturing companies. The application of an MES solution can be successful in a discreet manufacturing environment, only if the process in analyzed completely and the parameters that need to be monitored and the process metrics that need to be analyzed are determined, before choosing the structure of the MES application. An MES solution can lead to higher productivity, lower cost, better quality and enhanced flexibility, only if the MES application partner specializes in the design and implementation of such applications.
Here I would like to introduce I2DS to you. I2DS is an organization that specializes in MES applications and has a team of expert analysts that works on the process specific design of the MES application. After designing the MES application, tailor made to your needs, our team of experts implement the application for you and provide a complete change management program for the employees. This makes I2DS the most preferred MES application provider in the industry today. We treat every manufacturing process individually and this makes our solutions the best choice for you. If you think that an MES application can not work in your process, just give us a buzz and we will show you how an MES application can make your operation more productive and much more profitable. For a live demo of our applications and solutions just hit the Request Live Demo Tab on this page or you can also e-mail us at info@i2ds.com.
by I2DS | Nov 1, 2022 | Blogs
Given the same set of Organizational resources and External Environmental conditions, why are some organizations exceptionally successful, while others struggle to survive? Organizations that are successful lay stress on three major factors besides Quality, they are Speed- speed of delivery and speed of process, Productivity- productivity of the process and productivity of the personnel employed and last but certainly not the least Cost- cost of the entire value chain and operating cost. A concentration on increasing Speed and Productivity while reducing the Cost makes some organizations much more successful than their competition. Successful organizations include these factors in their vision/mission statements.
Speed of delivery and process change has become important to due to the ever decreasing Product Life Cycles and Time to Market. Productivity of the process and personnel is vital as it reflects the process knowledge and the ability to change the process and process output as required. Cost has been a vital factor ever since the advent of trade and commerce, but its much more important now due to the decrease in profit margins. So what has brought about these changes and how do you cope with them?
Technology has been a massive contributor to better speed and productivity and lesser costs. Organizations which have realized the importance of technology and successfully implemented technological advancements in their process have become global market leaders. On the other hand organizations that have been sluggish in embracing technology have paid a heavy cost leading to a loss of market share or even worse an exit from the market itself. Information Technology or IT is the key to value chain optimization and process excellence. It is only through IT that we can improve speed and productivity, while reducing the cost incurred.
Information systems integrate the process, which allows faster change, real time decisions, faster issue resolution, higher quality, lower operational cost, better process control and many more advantages. But the tricky part is that most organizations do not have a high degree of competence in developing IT solution, this leads to outsourcing. Choosing the right partner for IT implementation is a strategic decision and needs to be taken with caution. So who is the right partner for your IT needs?
I2DS is the right partner for you because our mantra is to deliver high speed and productivity at minimal costs through our information solutions. With our products and services, we can help speed your production line, we can increase your productivity where role assignments have more time to work on the things they are hired for instead of tedious data collection and analysis steps and ultimately we save you money. We offer a myriad of tailor made, process specific solutions such as- Factory MES, Communication Management, Manufacturing Excellence, Inventory Management, Safety Management, Quality Management, Equipment Management, Database Management, Process Automation and IT/ Software service. So if you are looking for an outsourcing partner that can help you optimize your process and achieve the results you desire, well I2DS is the best choice you have. So don’t wait any longer, e-mail us at info@i2ds.com and become faster, more productive and cost effective.
by I2DS | Oct 31, 2022 | Blogs
Have you ever wondered what is missing in your manufacturing plant? Why are operational costs still high? What is causing redundant expenses in the production line? Why is it that TPM efforts are not succeeding in your facility? These questions haunt Operations Managers on a daily basis. The abovementioned problems exist in all facets of the manufacturing industry and some implications remain the same irrespective of industry, but vary as per the level of industrialization. Even in factories that have completely automated equipment, there might be similar problems to the factory that has a completely manual process. No matter how complex a production process is, it still requires at least these things, 1) Equipment/Tools, 2) Raw materials and most importantly 3) Human beings.
Worker and employee training have helped lower the costs related to human errors and have helped organizations develop an environment for learning. Raw materials are generally outsourced and the suppliers have to comply with strict compliance a standard, which assures the quality of raw material is acceptable. Equipment issues however are neglected in many organizations; these issues contribute heavily towards factory overheads and high operational costs. The reasons why TPM efforts fail in Organizations are the lack of correct monitoring systems, lack of correct metrics and lack of Organizational commitment. The above argument necessitates the need for a comprehensive, facility wide information system, which has the capability to monitor equipment and help reduce costs.
Having access to real time data from the equipment can be beneficial in a number of ways. It would help obtain a higher degree of clarity and transparency, it would help in better preventive maintenance efforts, it would help cut costs due to redundant maintenance efforts, and it would help increase the up-time of the equipment and thereby result in a greater throughput. But the application of such a system is a tricky job and requires an expertise in Operations management as well as Information Technology. If IT is not one of your core competences you need to choose a partner who has the desired skill set to give you the functionality you require, at reasonable costs and help you manage the resultant change.
by I2DS | Oct 27, 2022 | Blogs
My experience with production lines has taught me that managing the WIP or Work In Progress, is considered a difficult task, more so because of the inability to track it, than any thing else. Operations Managers often complaint of many issues, such as, being unable to track the material, the shifting of bottlenecks, higher machine downtime, higher cycle time, higher material consumption and the list can go on and on. The reason why some of these issues exist or are perceived to exist is because of the inability to properly track the material on the production line, the inability to know the machine status in real-time and the glitches that appear in a supposedly rock solid planning due to a myriad of small yet unavoidable issues. It is this feeling of being in the dark, coupled with the unpredictable nature of day-to-day operations that make it hard to manage the work in progress.
But if we analyze the abovementioned statement, is it really the nature of operation or the actual work that is the problem area, or is it something else? Well, I believe that the nature of work and type of tasks have nothing to do with managers struggling to manage the work in progress. Yes, I think it is the lack of actionable and potent information that drives most managers crazy when it comes to managing the WIP. When you think about any process and by any process I mean any process, manufacturing or service, what makes managers fly is the information they have, to act upon and take decisions. Even in the most unconventional processes what makes them work is the information derived from the process and careful analysis of the process metrics. The need to have a continuous flow of information from the process has been realized by many industries.
However the actual work-in-progress has been neglected by most companies, be it the process owner or the IT firm developing so called solutions for them. I believe that WIP is an extremely important facet of any process in fact it is the blood that runs through the veins called machines and supports the function of the body which is the process. WIP should be carefully tracked, monitored and analyzed; this will help detect problems before they become serious and lead to an overall improvement in process efficiency and ultimately throughput. But, who can you rely on for developing an information solution that can not only help you analyze your WIP but a solution that can help you realize true gains out of your process? Well, for that you need a technology partner that understands operations management and the unpredictable nature of WIP.
For this very reason choosing a simple software company does not fulfill the need, you should consider someone who knows how a factory works, what the importance of process metrics is and how WIP should be managed. You need an automation expert that is well acquainted with how the flow in the factory happens and why bottlenecks get created. Having said that the most important part is to realize the need to have real-time actionable information from the WIP and then choose the right partner for your process. If you have any suggestions regarding this Blog or questions about how to manage you WIP just write into us at info@i2ds.com or just leave you comment on this web-page.
