by I2DS | Jul 10, 2023 | Blogs
APC or Advanced Process Control is a necessity for today’s Organizations for their R&D segment. APC is composed of different kinds of process control tools, often used for solving multivariable control problems or discrete control problem. Advanced process control involves control engineering, signal processing, statistics, decision theory and artificial intelligence. In simpler terms APC is a tool that enables real-time process development and process control. Presently organizations lack the capability of being dynamic in process control and development, increasing operational efficiency while keeping the cost low is a major challenge. i2DS’ APC is a comprehensive tool which helps experts in designing and programming Automation Logic to minimize Human Intervention in R&D and Production lines & real-time maintaining process parameters by integrating in-situ metrology to Tool Control System through i2DS Framework. Our APC provides you with real-time maintaining process parameters by implementing feedback loop from offline Metrology to Tool Parameters through Factory Network. We have made our APC flexible enough to fit the R&D need of your operations and give you the ultimate control tool for your process optimization. To see our APC tool in action get in touch with us right now and let us make process control and process development simpler for you.
by I2DS | Jun 29, 2023 | 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 | Jun 27, 2023 | Blogs
Operational excellence is highly desirable, and organizations strive to achieve it. But is it a static state of being or is it dynamic? Once operational excellence is achieved is it easy to sustain? Is the pursuit of operational excellence even worth the effort? Well let’s answer these questions one by one and try to gain clarity, achieving operational excellence and maintaining it is a dynamic process, you have attained operational excellence when your process is capable of meeting the requirements of external forces dynamically. Your operations has achieved excellence when your process knowledge is refined to state where you are aware of all parameters that potentially effect process performance and you are able to locate root cause of every performance related issue. A process that is excellent will achieve a state of equilibrium with market governed deliverables in real-time and without many grass root changes. An excellent process will deliver regularly on at least 3-4 of the 5 vital process performance parameters, which are Quality, Speed, Dependability, Flexibility and Cost.
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.
To sum up, let me revisit the topic again and reemphasize my thoughts on it. According to me operational excellence is well within reach if planned for and pursued sincerely. Once achieved operational excellence can be sustained if the process is equipped with the right technology and has the will and training to sustain it. It becomes worthwhile to achieve operational excellence simply because it shows that the organization would never settle for anything less than the best. If you achieve excellence you become best-in-class operation, which is a direct boost to your reputation and which would inevitably lead to better business. Please share your thoughts and suggestions with us about this blog, write into us at info@i2ds.com or just leave a comment on this web-page and we will get back to you.
by I2DS | Jun 26, 2023 | 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 | Jun 19, 2023 | 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 | Jun 16, 2023 | Blogs
In my experience the question being asked above is a fairly frequent one. We live in a highly technology driven world, information is what brings us together and it is information that has become the difference between success and failure in business today. An Organization that does not have the information about the external environment, that constitutes the customers, competitors and the market on the whole, and its internal environment that constitutes process capabilities, suppliers and personnel, is destined to fail in the future. Leading organizations around the world have realized the importance of data management and knowledge development, they have used Information Technology as a weapon to fight competition and attain a higher market share.
Companies lay great stress on finding out the information related to the customers, supply chain partners and competitors. Almost all FMCG companies today drive their operations based on point of sale data obtained from various retail stores. However concentrating only on outside information although important can be fatal if the internal operations are ignored. Organizations have to realize that the most important source of information is the internal operations itself. Data Management should be more holistic and cover all aspects of an Organization’s operations. For firms in the manufacturing industry that face strict compliance standards, being able to harness and process the operational data is crucial for survival itself. Best-in-class Organizations lay great emphasis on data management of internal processes as it helps achieve a higher degree of control and flexibility.
The trouble arises when an organization realizes the need for information and data management but does not have the capability to manage its data on its own. Not all companies have the capability or resources required to design and apply a Database Management system in-house. This leads to two major considerations, 1) whether the resources needed to manage data should be acquired? And 2) whether the development, application and management of the system should be outsourced. In my view there is a very simple answer to this question, if a firm wants to be profitable and achieve excellence in all facets of business, they should outsource any activity that is not their core competence.
Today there are a myriad of Database Management products and so called ‘solution’ providers, who claim to provide a tailor made solution for your requirements. But, if you are an Organization facing trouble managing data and don’t want to go for a standard package with limited functionality, then what should you do? The answer is you need to gauge your requirement and ask your self these questions- 1) Do we need a real time database management and data processing capabilities? 2) Do we require to Tap Data directly from tools to our MES or present System? 3) Do we require features Like SPC, APC, RFID integration, Inventory & Ops Management? 4) Do we need to monitor Safety, Quality and Equipment issues in real time? If the answer to all or majority of these questions is ‘YES’, then you need to consider I2DS as your strategic partner.
We at I2DS understand the prevalent issues pertaining to Data Management and Data Architecture and we are committed to work out the best solutions for our customers, our aim is to provide world class Information Solutions at reasonable prices. If you want your Data Management problems to disappear you should mail us right away at info@i2ds.com or Click on the Request Live Demo button on our web site. We assure you that with our solutions applied in your Organization today, you will become the leader of tomorrow.
