by I2DS | Jul 22, 2022 | 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 and assignable 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.
Even modern theories and systems such as TQM, Six Sigma, Lean and JIT, lay a lot of stress on management by facts. Many management theorists have stated and concurred the belief that what can be measured can be managed. The school of thought that advocates the use of facts and figures in management makes a very strong case, this is because it gives a factual and analysis based perspective to management and does away with managerial whims and fancies. But to be able to manage any process by facts and figures, it is imperative to have these facts and figures. Any process irrespective of its type, functionality or end product always has parameters that define it; every process generates data that can be measured to ascertain its performance. The use of standards, metrics and process generated data, for improving the process and better controlling it is what SPC or Statistical Process Control is all about.
TQM theorists and practitioners believe that SPC is the best way to manage and improve a process and that without SPC; a TQM effort can never be fully achieved. In the early 1980’s managers found the use of SPC very difficult as it required them to possess a very good command on statistical tools. This scenario has changed for good in the present SPC modules available for managerial decision making. Today there are SPC applications that can perform all the required calculations and provide the required information, this means that it’s the application that processes the raw data and the manager is saved from performing lengthy and time consuming calculations.
Most futuristic organizations of the world are moving towards the use of SPC applications for improving the over all process efficiency of their production units. The trouble is whether to use an SPC solution which is available off the shelf or design one that can be tailor made for the organization’s requirement. This is a common dilemma when it comes to any IT application; it is because besides the functionality there is a certain cost constraint involved in such decisions. Till now we have established the importance of an SPC solution and are stuck on the question whether to have a custom made solution or whether to buy a standard one? Well, for me the answer is quite simple, if you need a truly efficient SPC solution it has to be process specific, the analogy I am using here is also simple. Let’s say a patient has a unique medical condition, he cant rely on general medication for getting cured, he needs a specialist and a unique treatment for his ailment. Since every process is unique in nature buying a standard SPC solution can never prove beneficial.
I2DS is the best choice, if you want the Best-In-Class SPC application at a reasonable price.I2DS has the ability to understand your process needs and how an SPC application can benefit your operation. At I2DS we realize the value a potent and process specific 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 | Jul 21, 2022 | Blogs
The common notion in the minds of people is that software applications like the MES are more suited for large, automated plants, which are typically 100 million dollars, type of plants. This is a terribly incorrect notion, MES applications have evolved from expensive on-site applications to suave and low cost service like solutions. Gone are the days where MES projects used to last for a year or two from the establishment of need to the roll-out, acquiring MES applications has become easier and more cost effective than before.
Modern MES solutions are more like a product suite, which comprise various modules, these modules are quite flexible and can be deployed for diverse processes and functional areas. It is important for manufacturing organizations irrespective of their current position, to realize that the future will be much more uncertain, rife with global competitors vying for their piece of the pie. It is extremely crucial to embrace automating and integrating technologies like the MES to become more responsive and more agile. A typical MES module covers functional areas right from purchase/inventory to end-of-line production and beyond, it also integrates seamlessly with the current legacy applications and other enterprise wide applications such as the MRP or ERP. The idea for SME companies is to understand the implications of not having the MES, not in the status quo but 5 years down the line, a future perspective will help them realize the importance and need of the MES, today. For most manufacturers, cycle times will need to reduce drastically in the future, with a definite increase in the product basket being offered, this will be coupled with the need to customize most of the basic products on offer. To have this kind of agility, even smaller companies will need enabling technologies, which help individual functional areas collaborate more effectively. The need to have precise actionable information will increase drastically and the cost of bad quality will have far more adverse effects than today. In this age of social networking, any quality issue or product re-call can potentially kill a small player, even if all its customer base isn’t affected, the ones who are exposed to bad products can spread the word faster and more aggressively than ever before, the idea of containing the issue by swift re-calls and reimbursements is no longer a lucrative one even currently, the situation will only worsen in the future.
The key here is to appreciate the value an application like the MES adds both in terms of tangible benefits and intangible ones resulting from the aversion of quality issues and faulty production lots. The future of every manufacturing company will depend on how they embrace integrating technologies like the MES and how they use the information generated to become more agile and more innovative.
by I2DS | Jul 19, 2022 | Blogs
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 | Jul 15, 2022 | Blogs
Quality has become the back-bone of successful business operations today. Every OEM/manufacturer stresses that their product quality is far superior to their competitors. The nature of international business is such that quality has become an order qualifier and is considered the primary consideration by the customers. To have a superior hold on their quality issues, operations managers around the world look at Statistical Tools and information systems. Without the help of modern information systems, getting a grasp of quality issues and dealing with them in real-time becomes very complex and time consuming. A quality management system can help manufacturers get a hold on their quality efforts, but the application of such systems should be done with extreme caution.
Every process is unique and faces a distinct set of issues both long term and contingent. In such a case a general Quality Management System or QMS can prove to be an impediment rather than a facilitator of the Quality endeavor. What organizations need to understand is that the one size fits all theory does not work in the case of production processes and any IT application should be carefully designed specifically for the organization’s processes to bear fruition. There are however some generalizations that can be made pertaining to the basic functionality that a QMS should have, let’s look at them here. A QMS should be able to provide potent information about the important process metrics, highlight quality issues and help in root cause analysis. But the over-all application of a QMS would depend drastically on how the process actually is and what is the present orientation towards product/process quality.
An ideal QMS would be able to adapt itself to the process and provide its users real-time, actionable information regarding all quality issues, and help them by providing an SPC application to ensure any occurrence can be assigned a cause and can be analyzed with the adapt at the systems disposal. There are also certain value added features that a QMS can provide pertaining to performance appraisal, process appraisal, process/product improvement and overall process efficiency. These features and their applicability are a function of the process owner’s needs and the capability of the service provider. With the emergence of TQM, Six Sigma, Lean and Lean Six Sigma, the importance of Quality Management Systems has escalated, what companies need to decide is the level of proficiency and depth of analysis they want for their operation and then select a suitable partner to provide for their needs. To be reasonably successful in your operation also a QMS is a must, but to be the leader in your industry, the Quality of your QMS becomes quite important. So while selecting a partner for application of a QMS bear in mind what you need and how can the QMS provider meet and exceed your needs with their applications.
by I2DS | Jul 14, 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.
by I2DS | Jul 11, 2022 | Blogs
I have noticed through my experience and that of my peers that managing the WIP or Work In Progress, is considered a difficult task. 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 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.
