by I2DS | Jun 27, 2022 | Blogs
All modern management 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. Similarly to perform the production process they are using MES applications. MES applications are being used to automate and integrate the entire manufacturing operation, thereby providing a much better picture of the entire production process and facilitating better management. Ideally an MES application should have an SPC module in the core application, this further improves the functionality of the entire operation and facilitates faster and better decision making. But most companies that are in the MES space lack the ability to design and integrate an SPC module that would provide their customer the desired functionality. In such a scenario should an SPC application should be used separately from an MES or are there any other options available?
Well, there is always I2DS, Yes; we have been able to design various process specific MES applications for different industries, which have an in-built SPC module. We believe that an MES application should be a comprehensive management system that allows you to operate, manage and control your entire facility using just the one system and SPC is an integral part of it. We have a team of renowned experts in the field of SPC, Automation and MES applications and this makes our solutions the most advanced and user friendly applications in the industry today. So if you are Operations Manager or a COO reading this blog and you think that SPC is important for your Organization, don’t wait, get in touch with us right away and experience our superior applications. E-mail us at info@i2ds.com or just hit the Request Live Demo, Tab and prepare to be amazed.
by I2DS | Jun 23, 2022 | Blogs
There are two universal variables each organization deals with and it is these variables that determine the shape, size and future of the operations in every Organization. These variables are Market Forces and Internal Capabilities. Both these factors are constantly changing and interdependent, this means that every organization in the world keeps changing as per changes in these factors. In present day and age most operations in the world have become customer centric and Quality of products has become the most important deliverable. The above statement implies that now the market forces are stronger than ever and most successful organizations have realized this and have been able to successfully alter their internal capabilities accordingly. It is the pursuit of this dynamic equilibrium between market forces and internal capabilities that has cause a sea change to cycle time and TTM.
Due to smarter consumers and their short attention span, the cycle time required for product development and marketing it has become shorter than ever. The total time taken from the conception of a product till it’s ready to sell is called Time-To-Market or simply TTM. The market leader has the luxury of a higher TTM; the followers unfortunately do not have this luxury. For industries in which the products are outmoded or need updating continuously the TTM is even smaller for example the Software industry, FMCG industry etc. Shorter TTM means higher pressure on the R&D and Marketing function, but even the other verticals are also under a constant and ever increasing pressure.
So how do you survive in such difficult times? How do you ensure you can sustain under the adverse market conditions and still improve your bottom line? To reduce the TTM, it is vital to have MES applications that allow quick decision making and reduce cycle time. MES applications that are dedicated to your process will help you achieve the TTM you are looking for. MES applications allow seamless integration of all verticals in your production process and can help reduce the cycle time drastically. This happens because such systems help process information in real-time at all levels of management, thereby achieving a better and more cohesive development of products and services. But any off the shelf solution will not be the correct choice if you have a complex process and need to improve your TTM in a large way. You need a process specific solution that can adapt to your unique needs.
An MES application needs careful design and consideration of your process in every aspect. This application can help you achieve a flexible and highly adaptive operation, but the choice of the MES provider is a vital constraint to your success. Such applications can not be purchased off the shelf as general applications will never provide you the desired functionality. MES application design needs a combination of Operational expertise and Software design proficiency, these skills allow for an MES application that is process specific and can lead to great reduction in cycle time. If you have any questions about the pressures your Organization is facing to reduce cycle time and how to cope and better manage your process, please write into us at info@i2ds.com.
by I2DS | Jun 22, 2022 | Blogs
Why do we need process control? To what extent should the data be analyzed? Will my operation really gain anything from an automated SPC application? These questions arise in an operations manager’s mind whenever the topic of an automated SPC system comes up for discussion. Let us try and answer these questions and help our operation manager in distress. The first question seems a little irrelevant to me, because I am ardent believer in the saying, ‘what can be measured can be Managed.’ Without an SPC system it would be very difficult to separate assignable causes and non assignable causes in quality and process related events that occur. This absence of process data can cripple the entire operation, so the need of an SPC system is not a question for me; I think an SPC application can find its way in any kind of operation.
The second question is a very good question, the extent of data analysis? Well, there is no point digging for more data if you have a process under control and your process metrics are clearly known, understood and monitored by your current SPC application, this means that your process knowledge is sufficient. But if the process metrics are not well known or it is a new process then an SPC application that can measure all relevant process metrics is a good way to start. Having an SPC application not only facilitates better process control but also adds to your process knowledge and helps you get a much better information pool about the process. This in turn facilitates process improvement and leads to operational excellence in due course of time. Thus the data that needs to be analyzed completely depends on the type of process and the present knowledge that you possess about the process.
The third question asks us about the relevance of an automated SPC application, I believe that an automated SPC system has benefits that are multi faceted. To begin with an automated SPC saves precious time that is spent on calculating relevant parameters manually, they are more accurate and human error is eliminated to a large extent and last but certainly not the least, an automated SPC solution allows you to take real-time decisions. This makes an automated SPC application a much more preferred option for your operation. However, when choosing a partner for such an important you need to tread very carefully. You need experts to apply an SPC application and the future performance of your process is dependent on it.
I2DS is the best technology partner for you, 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 | Jun 17, 2022 | Blogs
Most companies have either an ERP or SCM or some other enterprise solution installed, but these solutions inherently lack the capability of managing Safety and Quality. So let me ask you at the very beginning of this Blog, do Safety and Quality management feature into the top priority list of your strategic portfolio? If Yes, then this Blog is meant for you, as you go on reading you will realize how you can turn your Safety and Quality goals into palpable reality, that too with minimum hassles. I believe it is imperative for any Organization to be a corporate citizen and fulfill its obligation to provide product and process, quality and safety. It is important for organizations to view compliance and excellence in Safety and Quality as promoters of long term profitability. For an Organization to be successful in the long term, such issues cannot be neglected, in-fact the attention paid to these aspects reflect the true character of an Organization.
Software applications like the ERP and SCM are more concerned with the quality of finished product, customer service and financial aspects of the business, they genuinely lack the depth and functional coverage of a complete quality or safety management application. These applications can only cover the high level objectives associated with these vital issues, without providing the granular clarity required to improve, leave alone excel in them. However, there are application now which are capable of exploring every aspect od safety and quality, right from compliance requisites to continuous improvement objectives.
Safety of the working environment and Quality of the final product/service are the most important contributors to the overall performance and profitability of an Organization. Safe working conditions have been known to boost productivity of the work force; it is considered the most basic work need by Maslow. The importance of Quality can never be overemphasized it is the most important order winner/qualifier in almost every industry. For some industries maintaining high standards of quality conformance is mandatory just to be able to ship the products. Even if such strict compliance standards are not present the need to maintain a higher standard for Quality is implied in order to achieve competitive superiority.
Having established the need to have high standards of safety and quality, we have to decide on the ways to monitor them. I believe anything that can be measured can be managed; this axiom of management applies to safety and quality as well. We need to understand the objectives and metrics associated with safety and quality, this will enable us to employ the right system to measure and control these vital parameters. Today Organizations are using Information Technology to better understand the implications of such critical issues and also to take corrective actions and practice management by facts.
You can employ our Safety and Quality Management Solution individually or as a part of the Manufacturing Excellence Solution, which also incorporates Equipment Issues and Fabrication Pass down. You can also integrate these applications within your current enterprise set-up, i.e. these applications can run parallel to your ERP and SCM providing a more holistic solution to your safety and quality concerns.
by I2DS | Jun 15, 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 | Jun 9, 2022 | Blogs
Operations Management is often the most neglected area in all Organizations, it is considered to be a firefighting tool only to be called upon in the event of any problem or mishap. I believe Operations Management should be considered a vital part of management and should be used to attain competitive advantage for the Organization. Operations Management affects all five competitive priorities, namely, Quality, Speed, Dependability, Flexibility and Cost. Rather than trying to manipulate the external environment to gain a competitive edge, organizations can gain a lot by concentrating on setting their house in order by laying stress on Operations Management Excellence.
Most modern theories of management lay stress on the importance of Operations Management and how crucial it can prove to be in the success or failure of an Organization. There are many books which describe the importance of operations management at a strategic level and how an operations strategy can achieve higher throughput, lower costs and profit maximization. The crux of these writings however is a very simple fact, which is, if you lay stress on doing things right the first time and try to improve your operations continually, you can improve your profitability and become the best-in-class organization.
For manufacturing Organizations, Operations Management is extremely important, its so because it deals with the most important activity of the organization, the production of the goods, that are sold in the market, under a brand name. Thus in manufacturing organizations excellence in operations management is highly desirable. Most successful companies have realized this need and are employing the most modern information solutions along with various management theories to achieve manufacturing excellence. Information systems are making Operation management highly sophisticated and pushing operations towards a six sigma level of efficiency.
Integration of the entire plant, process and personnel is vital for achieving manufacturing excellence. This integration can result only with the help of an information system that provides a seamless and holistic view of the vital process and personnel related parameters. This system should allow effective monitoring and efficient control for the entire process and aid real time decision making and action. There are many packages available in the market for Manufacturing Excellence, but is just any package the right package?
I believe every manufacturing process is unique; this is because of the fact that each organization has an inherent set of resources and unique environmental conditions. Thus a Manufacturing Excellence application should be process specific and not general. Every Operations manager gives importance to certain parameters, for the sake of this discussion lets say Quality, Safety, Equipment and Factory Communication. If the package available cannot capture the details of the parameters above mentioned, it is rendered useless for this particular Organization.
I2DS has devised a Manufacturing Excellence solution that can fit to your process and give you the power of monitoring and controlling the process parameters you consider vital. So if you believe that Safety, Quality, Factory Communication and Equipment issues are important cost centers and need to be monitored and controlled effectively, I2DS’ Manufacturing Excellence allows you to do exactly that. You have the capability to assign priorities and owners to each issue, see the real time actions and judge the performance of the entire process or the performance of individual parameters. With I2DS as your Excellence partner, you will never miss a vital issue and will be able to reduce the operating costs drastically, thereby achieving better profitability. With I2DS you can gain process excellence and this would help you become the Best-In-Class Operation. So open your doors to Manufacturing Excellence and I2DS, write into us at info@i2ds.com, and give us the opportunity to help you achieve excellence in all your competitive priorities.
