by I2DS | May 31, 2022 | Blogs
How much money do you think you loose due to excursions that occur on a daily basis on your production floor on a daily basis? Excursions that occur due to lack of planning, preventive maintenance and lack of process insight can become a major cost center. Also due to the highly random nature of excursions it becomes very hard to detect them and prevent them from happening. During a process simple or complicated, there are thousands of things that can go wrong, the more complex the procedure the more excursions that can occur. So, is there any way to detect a possible excursion and prevent it from becoming a major cost center?
Yes, there is a way. Process integration is the best way to achieve excursion prevention. The major area where an excursion is most likely to occur is generally at the interface of two subsequent operations of the process. This is because of the fact that the material under process changes hands during subsequent operations in terms of machines and personnel. With an integrated process the chances of an excursion happening become really slim, this is because there is a clear communication path and free flow of information in the entire process.
Theories like Total Productive Maintenance or TPM greatly emphasize the need for excursion prevention rather than the standard practice of excursion detection and subsequent corrective action. Most manufacturing processes in the world have become highly complex, to make it difficult for competition to imitate them, also almost every production process is unique in some way even though the equipment used might be similar to others. Information Technology and process automation and integration applications are helping organizations around the world exercise better control and achieve higher excursion prevention.
But just any ‘off the shelf’ application will not help you improve your unique process and changing the entire process to better suit the soft ware application does not make sense. A tailor made solution is required that has been designed to suit your process and then achieve the required functionality of excursion prevention. I2DS has been able to devise such solution which are helping its customers increase the effectiveness of their prevention efforts and thereby increasing their profitability as well.
Most systems lack the capability of tracking material through the production line; this may lead to a major loss in material and production time. There is an evident need for a solution that can help track material throughout the production line and I2DS has just the solution for this problem. We have developed a unique Inventory Management Solution, which allows you to track your material even after it leaves the Ware-house. Our system gives you the ability to track the exact location of material, anywhere and everywhere in the production line, right up to the finished goods stage.
Our solutions are capable of collaborating with your existing ERP system to give you better control and complete traceability for your material. Our system is in-line with JIT theory and helps you monitor the inventory at each and every step of production and insures you not only detect but prevent any excursion that might happen. Our system allows you to detect excursions faster and thereby helps you to prevent losses which might have otherwise occurred. So if you are interested in cutting your losses and improve traceability of your material, contact us right now and get a free demo of our path breaking solutions, e-mail us at info@i2ds.com.
by I2DS | May 30, 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 | May 26, 2022 | Blogs
Thirty years back, if someone was to walk up to my dad, and say “You know what, computers can make your factory a safer place”, my father would have probably laughed and gave him this anecdote- that safety is not achieved through some computer thing, its achieved through careful assessment of risks, constant monitoring of the workplace, training of workers and using proper PPE and guards. I guess, he would have been right to say it then, but, times change and old ways surely become obsolete. Today, IT systems can not only make factories much safer, it is these IT applications that actually control and improve the safety conditions at a work place.
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 Maslow’s theory about ‘Hierarchy of needs’, Safety, at the workplace is the most 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.
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.
At I2DS we truly believe in the Mantra- ‘Safety First.’, we have developed the most comprehensive Safety Management Solution for Organizations like yours. Our system has the ability to integrate the safety efforts of your entire organization on a single platform; it will ensure that safety is not just a priority on paper, but in practice. Our system gives you amazing functionalities such as, the ability to plan and organize safety events, provide trainings, assign owners to safety tasks, view safety events such as Audits as they happen, prioritize safety issues and so much more. If you really believe Safety is your prime concern, then don’t wait, get in touch with us right now and help us make your working environment safer than ever before. Our e-mail id is- info@i2ds.com, or you can also hit the Request Live Demo link and we will get back to you.
by I2DS | May 25, 2022 | Blogs
Operational Excellence, a lot comes to mind when this term is mentioned, it is what all organizations wish to achieve, and they strive for and are in constant pursuit of. The ends of such a pursuit are pretty clear, which would be becoming the Best-In-Class operation, Profit Maximization, Elevated levels of throughput, Cost minimization and Quality excellence. However, the means of achieving the same are process specific and need to be handled with a great degree of individuality and extreme caution. Management practices like Benchmarking, TQM, Lean etc. will only lead to improved competence, but to achieve operational excellence, the approach cannot be generic, it has to be tailor made to suit your operational set-up and should be as per your internal capabilities and external environment.
Achieving process excellence needs an Organization wide commitment, starting from the very top. When the pursuit of excellence becomes a main focus area of the top management, achieving excellence will become a lot easier. The top management should understand the reasons for having an excellent operation and truly believe that through sustained and coordinated efforts achieving operational excellence is well within reach. Top management should remain pro-technology and understand that one of the key contributors to achieve increasingly better performance is through the application of end-to-end information systems, which have the capability of monitoring, controlling and executing the entire process on a single platform. Information solutions help operations gain clarity and makes coordinated efforts possible. Achieving operational excellence becomes less challenging when the process functions as a single entity, this integration is possible only through information solutions that have the capability of integrating the process right from, receipt of raw materials to dispatch of ready to ship products.
Besides management commitment and technology, there are other key contributors to the pursuit of excellence; they are- employee training/participation, Quality means 0 defects philosophy and management by common sense. These factors are equally important and can mean the difference between success and failure of the entire endeavor. However, for this article my major area of concern remains the importance of technology and even more so the role of IT in the pursuit of Operational Excellence. So coming back to the area of focus, I believe information solutions can help reduce cycle time, operational expense, inventory and operational errors greatly. IT should be considered the foundation for building a strong and profitable process. Top management should consider developing either in-house IT capabilities or if they want to concentrate on core competencies they should consider outsourcing IT, but only to a capable and well equipped partner, with relevant industrial experience and expertise. The major benefit of employing an IT expert is that the resources of the organization could be used to improve issues related to the core competency and an expert can design a process specific solution and provide change management and employee training as well.
Your pursuit for operational excellence can benefit from just one word, which is MES. Yes, MES applications are those information technology applications that provide an integrated platform, which allows the execution of the entire production and QC process on a single system. The MES automates the entire facility and prevents the formation of bottlenecks. An MES application allows for real-time decision making and allows the operations manager to stay ahead of bottlenecks.MES applications are being employed by the best-in-class organizations to increase their throughput and ultimately their profitability. However the level of throughput you are able to attain for your plant depends on the partner you choose for the design and application of MES at your facility. At this point I would recommend that you consider I2DS as your MES design and application partner continue reading and you will know why.
I2DS has the most respected, Factory 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 | May 24, 2022 | Blogs
Data is the life blood of any manufacturing operation; it is required at every stage and across all stages of the process. Data Management is the heart of any professional operation. Data collection and analysis have come a long way since the first CNC machine ever came into existence. The need for equipment and tool data has been increasing due to the emphasis on SPC and automation place by much modern management and manufacturing theories. TQM and Lean Gurus such as Deming, Taguchi, Juran and Shingo have placed great emphasis on management by facts and prevention by better process control. This emphasis on management by facts has further intensified the need to pull real time data from the process and use it for better control and improvement.
But pulling data from equipment is easier said than done, there are many complexities involved in pulling process data from tools and equipment which arise due to their make, data systems, compatibility, user interface and programming language used. To complicate matters further Legacy systems being used in most factories are incapable of adapting to new process and data requirements. But equipment and tool data remains the most desired and sought after data for better process control and subsequent improvement. So what can be done to free this trapped data and present it to the right person? To be able to access the tool data you need a partner that understands your data requirements and is capable of providing this elusive data in the right format at the right time to the right person.
I2DS is the right partner for all your data tapping needs, let me elaborate why as we go ahead. I2DS has the capability to automate your entire operation irrespective of the genetics of your tools and equipment. Our automation team specializes in factory automation, data tapping, EDC and SPC. An automated factory has a comprehensive SCADA (supervisory control and data acquisition) application that enables effective HMI or Human Machine Interface. Our wide range of amazingly flexible products is what you require for applications like Tool Integration, Data Tap, SCADA, RFID implementation, SPC and EDC applications. So don’t waste your precious time, get in touch with us now and let us make your data available to you, from wherever it is trapped. E-mail us at info@i2ds.com and we will transform your factory and give you the edge that you deserve
by I2DS | May 23, 2022 | Blogs
Before you begin reading this Blog, please stop and think for a moment how much do you value work place Safety and product Quality? I know these are two separate issues but they are interrelated in many ways, you will gain clarity as you continue reading. Work place Safety is considered the most basic need of any worker or employee, it is considered essential for being able to perform any kind of task/work. Imagine worrying about something falling on your head while you are preparing the production schedule or writing a report for your big-boss. Quality on the other hand is partly dependent on the level of comfort the workforce feels. It has been seen that a safe and comfortable workplace can lead to better product/service Quality. Coming back to my original question, if you really believe that it is your organizations responsibility to provide a safe work place and better product quality to your end consumer, please continue to read.
Safety at a work place is neglected not only in the third world countries even in countries like the USA and in Europe. People feel that the safety norms are just too difficult to follow and too expensive to implement. But let me ask you this, what price can you put on a human being’s life? If you don’t have an answer for this question, I believe you will agree when I say that workplace safety has to be ensured at all cost. But there are cost effective ways to achieve the desired levels of Safety at the work place but more on that later. Coming to the topic of product and process Quality, gone are the days when Quality used to be the order winner, it is now considered an order qualifier. Quality is perceived differently in different industries and for different processes. The one thing that remains uniform irrespective of line of business or type of process is the dependence of quality on the process and process metrics. It is vital to reach a zero error stage in product/process quality and maintain the level, if you are to excel in business.
Now that we have understood the sheer importance of Safety and Quality, what are we going to do about it? Well, for starters let us look at the possibility of the role that IT applications can play to help to achieve Safety and Quality excellence today. Yes, IT applications can help you monitor, control and improve on every safety and quality issue in real-time. These apps are transforming the way these issues are managed around the world and preventing major incidents from occurring and eliminating minor ones. These applications help prioritize events, monitor metrics, highlight major issues and aid real-time decision making and issue resolution. Such applications are the future of workplace safety and process/product quality. They help you perform online trainings, schedule maintenance activities, assess quality metrics and assign ownership. Such applications really meet tomorrow’s needs today. If you have any questions as to how such applications are beneficial in you industry, do write into us at info@i2ds.com and we will be glad to help you.
