by I2DS | Jul 13, 2021 | Blogs
Over the years Manufacturing has become more precise and process dependent, any deviation from the set procedures and norms can have dire consequences for the factory. In operations like Semiconductor manufacturing a spec of dust can destroy an entire production lot, such controlled and highly automated environments call for much tighter and fool proof production and process control, than ever required in older more manual processes. Modern manufacturers rely on early detection and prevention of any deviations and excursions in their fabs, generally the burden of such activities is borne by an IT application, which in most cases is the MES.
MES applications are employed not only to execute a process in entirety, but also to exercise tight control and precision in workflow. In automated environments where human intervention is less than 10% the MES is expected to communicate directly with process equipment and report valuable process information, in a user-friendly manner.When it comes to issues, such as deviations in the process, the MES should be capable of detecting and highlighting the issues in real-time so that they are noticed by the requisite personnel.In paper-based and legacy MES systems issues which were detected, got reported only when they could no longer be controlled, which made the entire process reactive in nature. These issues have been mitigated by the modern MES which not only detects issues, as or even before they happen but reports them instantaneously to multiple individuals, making sure every issue is dealt with before it escalates and becomes a major problem.
This unique capability of the MES to act as an interface between workforce and equipment allows it to be an ideal platform for root cause analysis and process control. Since every deviation right from material quality to equipment errors are reported, it becomes easy for process owners to pin-point the location of the problem, once the problem is localized, it can then be analyzed using the MES by either drilling down the historical/genealogy data or simply asking the activity owner for explanations. Once a problem is analyzed both subjectively and statistically, its root cause can be determined by allocating assignable causes or special events, like the material thickness being 0.2 mm more than usual etc.
Once a root cause of an issue is determined, it can be archived in the system as a problem type and can be inculcated in the company’s knowledge system, so that whenever similar issues occur the workers can reference the system to find the best way to deal with the issue. This power of pro-activeness that the MES brings to the table is unparalleled and just can’t be matched by any other application, which is because the MES is designed for executing the process and not for reporting financials or planning inventory, this statement however does not mean that the MES cannot perform these functions as well.
Sticking to the topics, having served in Operations myself, I believe for any operations professional, knowing what the problem is, and where it occurred in the process itself is half the battle won, the MES goes a step further and provides information to cross-reference the issue with other similar ones in the past and the specification for that particular jobs. Knowing all this a skilled team of operations professionals can not only detect the root cause of an issue but also increase the money-making capacity of an operation by preventing issues from ever occurring again.The MES is an ideal solution for mature-automated processes, which are in pursuit of improving continually and are practicing Lean or Six-Sigma.The MES would actually allow such processes to channel their improvement efforts towards the areas that need greater attention, thereby reflecting results faster. So if you are looking for better process control and enhanced problem detection/correction, think MES.
by I2DS | Jul 5, 2021 | 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.
by I2DS | Jul 2, 2021 | Blogs
Are you unable to meet the growing demand for your products? Do you think you are operating much below your plant capacity? You want to improve the efficiency of your operations but don’t know how? All these questions will be answered as we proceed forward in this blog. Organizations lay great stress on increasing the demand for their products and often fail to consider the implications exaggerated demand might have on their production line. It is often seen that promotions and intense marketing causes the Bullwhip Effect and forward buying. In such cases the efficiency of the plant becomes indeterminate, due to the skewed nature of demand. However if the demand remains buoyant on a regular basis without a noticeable negative trend, the importance of improving the efficiency of current operations becomes critical before considering an increase in the plant capacity.
Complacency and lack of process knowledge are the two major reasons for decreased efficiency among others. Being complacent implies that the management believes that there is no further scope for process improvement and thereby no chance of enhancing efficiency. But this belief is self destructive in nature, as the great gurus of TQM have rightly proclaimed “No process is ever perfect”, which means that there is always a scope for improvement. Organizations should strive for integration of internal and external processes and avoid complacency. Lack of process knowledge is even more lethal, as what can’t be measured can’t be improved. The best way to improve process efficiency is by the use of technology to integrate the process and make the process related metrics available to all levels of management as required. The degree of integration of various facets of the production line will determine the degree of improvement in efficiency.
The need of the hour is to have IT solutions that enable you to better adjust with the market forces and still be able to achieve optimum efficiency, so that profits of the firm are not affected. I2DS has been able to provide powerful Information solutions to its customers and helped them achieve the efficiency that they desire. We believe that only on integrating the Factory Operations can an organization get a handle on what’s going on in their factory and how to better control and synchronize the efforts. Our solutions give you a better picture of every activity that happens on the floor and generate real-time reports that enable effective decision making. Our path breaking MES product gives you a common platform for all your operations, this enables integration and real time decision making. Every lot that is run can be configured from the beginning to EOL; right from selecting lot-path to lot-recipe, each lot can be tracked irrespective of current location. EDC and SPC features allow better control and quality; they also enable real-time analysis and help better and faster implementation of corrective action plans. It helps generate reports that are available for analysis as and when required.
All in all our MES solution gives you the functionality of optimizing and integrating your operations right from planning to execution, in real-time. But the benefits that I2DS can provide to your factory ops don’t stop here, we have made it our mission to go beyond the realm of basic MES and our Manufacturing Excellence Solution does exactly that. I2DS’ Manufacturing Excellence allows you to monitor all the major issues on your factory floor which include, Quality, Safety, Equipment Issues & Communication Management. This solution helps you gauge issues besides regular factory operations which are just as critical as the operations itself. Each and every issue that is related to Quality, Safety & Equipment becomes very important as neglecting them can lead to high and unwanted cost implications. Our Manufacturing Excellence solution allows you to report, track and analyze all these vital issues and make real-time decisions. Equipped with these powerful tools you can achieve a highly robust, integrated and optimally efficient operation. I2DS’ endeavor is to help customers achieve operational excellence has lead us to develop even more amazing solutions right from Database Management to a complete IT outsourcing partner. So if you want to feel the happiness that results from a factory that is working at its true potential write into us at info@i2ds.com.
by I2DS | Jun 29, 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 | Jun 28, 2021 | Blogs
Quality, Speed, Dependability, Flexibility and Cost, these are the vital competitive priorities that are considered most crucial for Organizations today. All these parameters are dependent on the availability of relevant and potent information. It is the acquisition and manipulation of the right information that has helped market leaders get the no. 1 spot in their respective industries. To acquire correct information, data collection, database management and data processing is mandatory. Organizations today lay a great emphasis on collection of data generated both inside the organization and outside.
Let’s first consider the importance of Data, its management and why is it so important to have robust data architecture? Each Organization in the world generates large volumes of Data every day, every hour, every minute; practically all the time. However this data becomes useless if not stored in a proper Database and not processed in a strong Database Management System. Today IT is the biggest concern globally and opposed to normal belief these concerns are not being eliminated rather they are escalating, as the products being manufactured worldwide are becoming more and more complex and the need to have the right info as and when required is more intense than ever.
The process of achieving a robust IT infrastructure begins with the purchase of the right hardware, followed by the correct software applications. The right database architecture and features like, data mining, data processing and data reports are very important for a successful IT implementation. At I2DS we have a strong belief that the results achieved today should amplify and improve in the future. We provide the best knowledge management services in the industry today, because we plan for tomorrow by applying solutions today. With I2DS as your Data Management partner you can achieve the desired level of data proficiency today and also plan for the future. We are committed to providing the right solutions for you.
I2DS provides many solutions and services such as- Data Management, Factory Automation, Factory MES, Manufacturing Excellence and IT/Software services. Our verticals have been designed specially to provide integrated platforms, which have the functionality of converting raw data to information and providing seamless information to achieve smooth learning resulting in an Organization wide Knowledge Base. So if you are an Organization that plans for future success with the application of right solutions today, if you wish to incorporate Organizational learning in your culture, I2DS is the best choice for you. Just e-mail us at info@i2ds.com and we will get back to you with the best possible solution for your data management needs.
by I2DS | Jun 25, 2021 | 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.
