by I2DS | Nov 18, 2021 | 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 16, 2021 | Blogs
Throughput, Operational Expense and Inventory are three major concerns for any manufacturing Organization irrespective of their end product, process and environmental factors. An organization can attain the goal of Profit Maximization only when they are able to minimize the Operational Expense and Inventory costs and at the same time increase Throughput. Throughput can be described as the rate at which a system or a process attains its goal, in business the goal being profit maximization, through higher sales and lower inventory. A high throughput indicates that the sale of the produce is high and the inventory is low, which basically means that the profit is being realized faster per unit of product sold. A high throughput is extremely desirable especially in present industrial environment, where product preferences change in a fort night and a product that was hot yesterday becomes obsolete today.
Companies today strive to achieve a dynamic equilibrium between external market forces and internal operational capabilities. In order to enhance the throughput it is important to consider the impact of all external and internal factors on it. Besides the application of management theories, Quality management systems, Poka Yoke (fool proofing), 5S, 7S etc., it is extremely important to realize the nature of your production process and the role that technology plays in it. All management theories that have come up in recent times have emphasized two major pointers, one- Management by facts and two- Use of Technology for better information management. To increase your throughput you need to assess the technological requirements and capabilities of your process and understand the supposed increase in throughput that can result from a technology up gradation.
On of the major reasons for the ever-changing bottlenecks in a manufacturing plant is the lack of proper communication and lack of clarity. Bottlenecks are the main deterrents to achieving a high throughput, so as logic would suggest it is imperative to eliminate bottlenecks to attain a higher throughput. The question is how do we eliminate the root causes of these menacing bottlenecks? Well, the answer is quite simple it’s- 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 | Nov 15, 2021 | Blogs
I believe that the pursuit of process excellence is quite a complex and in most cases a very unique endeavor, however the way in which it is approached can be simplified. Process excellence in manufacturing is greatly influenced by the level of knowledge the plant/factory possesses, pertaining to the way in which the process works and the way in which seemingly separate and independent activities eventually add to the value of the end product. Today, I am going to present a simple three step ladder for achieving world-class levels of process performance and the role IT applications can play in the better execution of these steps from an economic and ease of operation perspective.
THE LADDER OF PROCESS EXCELLENCE-FIRST STEP: KNOW WHAT.
The first step involves establishing what exactly is done in your process, this can be done through a WIP profile or a WBS i.e. a Work Breakdown Structure or any means which would help understand how various activities performed in the process deliver value at the end, in the form of a finished product. This stage requires the formation and careful documentation of SOP or Standard Operating Procedures for each value adding activity. To complete this step a close involvement and contribution of the process owners is mandatory. The step gets completed when a comprehensive, written account of the process (as-is), is established and linked to the way in which each activity contributes to the bottom-line. Here the objective is to understand the status quo of the process and quantify the activities in terms of their contribution to the economic profits attained.
THE LADDER OF PROCESS EXCELLENCE-SECOND STEP: KNOW HOW.
This involves careful scrutiny of each activity to understand which Process Metrics translate to value in terms of customer satisfaction, Quality, Throughput etc., the metrics can range from Efficiency to CpK to OEE to any metric which, when influenced can effect the bottom line directly or indirectly. It is at this stage improvements can be pursued through TQM, Quality Management Systems, SPC modules. The know-how results from the derivative knowledge attained through these improvement efforts would help process owners understand how the process reacts under various circumstances and contingencies. This step aims to chalk-out the pain points of the process and analyze the root causes for all of them. This step will help deal with all common issues which occur on a day to day basis and will help form an action plan to deal with these recurrent causes, by either eliminating or avoiding the root causes of the issues.
THE LADDER OF PROCESS EXCELLENCE-THIRD STEP: KNOW WHY.
This step involves ramping up the the pursuit of process excellence by looking at process wide improvement through interdepartmental and cross-functional collaboration. It is not uncommon to begin implementation of Lean, Six-Sigma, JIT and other such complex strategies, techniques and tools. The aim here is to reduce process anomalies to the extent where errors can only occur due to contingent issues or non-assignable causes, which are beyond the control and reasonable comprehension of the process owners. By the end of this stage process owners should know exactly why issues happen in their process, and should be able to control or mitigate them before happening or escalating.It is at this juncture that the IT applications like the MES which have the capability to integrate the process become very important. Through these applications the cumbersome task of obtaining, maintaining and analyzing process data, becomes automated, this helps faster decision making, leading to early detection and prevention of issues and errors. Due to the collaborative and flexible nature of these applications a granular view of each and every process activity can be obtained. The ‘Know Why’ step is the most crucial for the manufacturing process, as only when a process knows exactly why events occur in the way they do, there can be positive momentum for continued improvement and positive and profitable change.
For processes which do not face continued pressure from market forces and technological developments, the ladder is quite linear and process excellence can be realized when the third step is reached and maintained. But for manufacturing processes which face turbulent market and technological forces, the ladder becomes circular, as due to the constant change, the level at which each activity and process element is located might be different. This condition calls for continued monitoring of each facet of the process and evident and constant effort should be made to reach the third step for all process activities. The pursuit of Operational Excellence, especially in complex processes is benefited by MES applications, as they make transition from one step to the other, seamless and thereby less painful. So if you think your process needs improvement or if your process is already mature and seemingly profitable, analyze it against the steps mentioned above and decide if its capable of pursuing excellence, if so don’t forget the importance of IT and specifically the MES.
by I2DS | Nov 11, 2021 | 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 | Nov 10, 2021 | Blogs
Information Technology is one of the most important areas of strategic planning and decision making for modern day organizations. IT decisions become even more critical because the top management of most organizations have limited knowledge of IT applications and relevant costs. All organizations feel the need to implement better IT infrastructure, but how to go about it, remains a crucial question. In most organizations IT services are outsourced, this makes sense considering the need to concentrate on core competencies. But while outsourcing IT services and applications it is important to understand the implications involved and take a decision after weighing the pros and cons of the situation.
It is indeed necessary to implement better IT infrastructure and have the operation of the organization automated. However, one should remember that once a mistake is made in choosing the right application or the right technology partner, it would be very difficult to deal with repercussions if the project does not work as desired. Even when purchasing a simple inventory or accounting software, it is important to understand the functionality that is desired and the functionality being offered by the selected product. As IT products become more advanced, the process of choosing the right application becomes more and more complex.
For companies that manufacture products, irrespective of their process, an MES application is highly desired to achieve a high level of automation and integration. There are many players in the MES market and all of them claim to have the best product. But what you need to look out for is whether that MES application suits your operations or not. Buying an Off The Shelf MES application has many implications, such as, there would be a need to change your process to suit the application, due to the changes made in the process the level of resistance received from the work force will be a lot higher and there are many other problems that may arise depending on the application selected and the degree of change to be made in the production process. I am strictly against the philosophy of ‘One size fits all’, especially in the case of MES applications.
I think it is easier to design an application that can automate and integrate the present process, as is, without making substantial changes in the process. Tailor made MES applications have proven to perform better and face lesser resistance from the work force. While making the decision of acquiring an MES application for your Factory, please remember that you should work with a company that understands operations in your industry and is willing to design a product to improve and integrate your current operations rather than change it completely. I2DS is one such company, we believe that every production process is unique and has different internal and external environments. We believe that a thorough study of a production process and an in depth research of the entire operation is required before designing and implementing an MES application.
I2DS has the most revered team of professionals both from IT and Ops Management background and our team of experts design our MES applications to better suit your process. If you need an MES application, get in touch with us and we will guide you towards a better more efficient solution, which will truly fulfill your needs of automaton and integration. We will visit your plant, analyze your process and then guide you towards an MES solution that will deliver the desired functionality. So what are you waiting for, e-mail us at info@i2ds.com or just hit the Request Live Demo, Tab and we will surely get back to you.
by I2DS | Nov 9, 2021 | Blogs
What helps the Organizations that are market leaders get to the position they are at? After wondering about this question myself, I realized that there is one major common factor, Evolution. Yes, the organizations that have made it big have all kept evolving, just like human beings, but only much faster. Organizations that have been proactive in their efforts to understand the needs of their customers and change their products and services accordingly, have been able to capture a larger portion of the market share than those who decided to stick to their old ways of doing things. Companies that spend a higher amount on R&D, also experience a higher volume in sales. It is through systematic and well funded R&D efforts that companies of the modern world have been able to devise much more sophisticated products and services and generate better business than their competitors.
But just having an R&D Lab is not a panacea for all future needs. It is extremely important how you manage the operation of your R&D facility and whether you have effective control on the process. R&D facilities have become more efficient by using technology and IT for managing operations. LIMS or Laboratory Management Information Systems are helping many Labs achieve their diverse objectives. Due to the dynamic nature and needs of an R&D facility no standard LIMS package can be suitable for your Lab. A Pharmaceutical lab has completely different objectives and operational needs than lets say an Aircraft development lab. This makes the design an application of LIMS a highly process specific and complex task.
The core function of LIMS is sample management; this includes the request from sample from the customer, the process of sample creation and also the tracking & delivery of sample to the customer. This requires data management expertise that is compliance oriented and process specific. A LIMS application can also have features beyond sample management, such as, equipment integration, electronic data exchange, export to excel/spreadsheets, audit management, barcode/RFID applications and the list virtually is endless. The presence of a good sample management application is pivotal for a successful LIMS system as the most important operation of any manufacturing R&D Lab is sample generation as per customer specs, effective sample creation and timely delivery of the said sample.
I2DS has successfully implemented the best-in-class, process specific, LIMS system for its customers. We have the expertise required to understand the diverse needs of different operations and design our solutions accordingly. Our sample management provides the desired functionality to our customers through effective data management, sample requisition tracking, material flow tracking, equipment issue resolution, Quality control, Inventory management, scheduling tools, sample analysis and a comprehensive database related to approval, rejection and compliance matters related to a particular sample. With our LIMS you can rest assured that your R&D facility will be working at optimum efficiency and achieve the desired results for your customers. So if you want to be a leader of innovation and achieve the coveted spot of market leader, I2DS can help you in this pursuit of excellence. All you have to do is e-mail us at info@i2ds.com and we will take care of the rest.
