by | Jan 30, 2019 | Blogs
TQM, Lean, Lean-Six-Sigma and Six Sigma are various theories of Operations Management or management on the whole that are helping organizations become more efficient and profitable around the world. I believe that these theories or management philosophies have a lot in common and should be pursued in spirit and in action. We should try and understand the end goal of these theories rather than trying to implement them blindly without proper consideration. These theories should be treated more like guidelines rather than a set of rules or do’s and don’ts. What all these theories tend to stress on is the reduction of operational costs, increase of throughput, attention to Quality, better relationships and involvement of customers, employees and suppliers and above all the pursuit of sustainable profitability.Understanding what these theories mean to achieve and finding the right platform to do so, is crucial for a FAB which is both flexible and profitable.
These theories lay emphasis on understanding the external environment and internal capabilities and achieving a dynamic equilibrium between the two. The approach to achieving this end goal is different in different theories, but the goal is the same. One major pointer that is emphasized in all modern management theories is that management should be fact based, that management decisions must be based on hard evidence and not managerial whims and fancies. The fact based approach brings me to the topic of my blog, which is implementation of management practices through IT applications.
IT applications can prove to be an effective way to apply and practice management theories. The beauty of such IT applications is that they can be tailor made for your process, which makes it easier for the staff to implement and can help improve the operations in the future. Depending upon the industry, IT applications can be programmed to monitor all vital process metrics, analyze the process performance, impart training, aid communication, facilitate supply chain integration, control production, improve safety, achieve quality excellence and the list can practically go on for ever. We need to understand that IT applications are not and elixir to our problems but are tools that can help us better resolve existing problems that we face on a day-to-day basis.
The idea is to implement IT applications in such a way that they facilitate real-time, fact based and potent decision making at all three levels of decision making i.e. at the Strategic level, Tactical level and at the Operational level. The design of the IT application should be such that it can suffice the decision making needs at all three levels and yet be comprehensive in its reach throughout the Organization. IT can help any organization and at any desired level of management, the need and scope of IT applications remain debatable and are best analyzed when considered for a particular process. My agenda here is to highlight that IT is a great tool because of its speed, agility and accuracy and should be given a consideration by all Organizations who are in pursuit of Operational Excellence and Profitability. I do not believe in following any management theory blindly without understanding its possible outcomes and neither do I promote blind faith in IT as an ultimate cure for all management problems.
I believe it is important to understand what your business needs to achieve the goal it has set for itself, besides the obvious goal of profit maximization. I strongly advocate fact based management and believe the IT applications can help achieve better results in a faster more organized manner. However, it is very important that before jumping to a so called IT solution we analyze our needs both external and internal, we understand the problem areas or pain points and then decide how and to what extent an IT platform can help appease our needs. I would like to conclude by reemphasizing a few pointers that I believe should be a part of any endeavor made towards improving management and improving profitability, they are, never choose a management practice blindly, use management practices as guidelines, try and improve profitability and quality and above all consider IT as a vital tool available to achieve your goals. If you have any questions or comments about this blog feel free to write to us at info@i2ds.com or just leave a comment in the comment box and I will get back to you.
by | Jan 30, 2019 | Blogs
Mura, Muri and Muda are the three types of wastes we see in Japanese management theories. Mura corresponds to unevenness in production, Muri is overburdening the workers and production process and Muda is non value adding work which attributes to waste. We often forget the importance of detecting the defects that cause these wastes. Finding the root cause of a particular waste type may prove helpful in eliminating the waste from the process, or at least lead to a considerable reduction in the waste being produced. All three wastes mentioned above can be witnessed in any typical manufacturing operation; these wastes are the major cause of loss of productivity and process down time.
Even in preventive maintenance programs the stress is laid on trying to increase the machine uptime and the final product remains neglected to an extent. In order to reach the desired standard of compliance and reduce the waste being generated it is imperative to analyze the defects being encountered during the production and try and detect the root cause for them. Defect management practices not only ensure steady production but also boost quality and reduce down time.
To effectively manage and control defects a Defect Management System should be employed, either individually or as a part of a bigger integrated application such as an MES. The better way of implementing the defect management system is having it integrated in the MES itself to give a better result due to the integrated nature of the application. This way the entire production process remains transparent and it becomes easier to identify the defect and its root cause. MES applications today have become advanced and can accommodate such applications as defect management. But the question that remains important is, which MES product is suitable for your process?
Well, the answer is quite simple; the best partner for your MES implementation and defect management is I2DS. Let me explain why, I2DS is one of the few companies in the industry that has a team of experts in Operations Management, it has developed the most sought MES application and they are the leaders in design and implementation of Defect Management Systems. These inherent qualities of I2DS make it one of the most sought after solution provider in the Manufacturing Automation industry. However actions speak louder than words and we would want you to see how effective our systems are and then make your choice. So if you are struggling with defect management and want a company that can understand your process, get in touch right away and make your production more productive. Our e-mail is info@i2ds.com, you can also leave your query in the comment box and we will get back to you.
by | Jan 30, 2019 | Blogs
All Operations professionals know and would agree that no matter how fool proof a production process might be there is always a possibility of an excursion, due to the contingent nature of day-to-day operations. The later an excursion is detected the more loss it causes. Detecting an excursion becomes even more important in discreet manufacturing as every product is different and tailor made. Even in an HMV production line an excursion can cause a massive loss if it remains undetected, thereby causing both financial and non financial loss. The financial loss caused by an excursion can be calculated, but the non financial loss, such as loss of customer goodwill, loss to the brand value, product replacement and product recall can permanently damage the image of an Organization.
Each Lot that is produced is of great value to the factory and any excursion during production process is a definite loss. It is imperative to be proactive in checking all production requirements are appropriately filled even before the material leaves the Ware-house. Being reactive will only lead to analysis of the loss that has already occurred rather than preventing it. Today most Factories are employing standard ERP systems that give material traceability to and from the warehouse, but what if the excursion occurs during production or when the material has already gone through the first stage of processing? Most systems lack the capability of tracking material through the production line; this may lead to a major loss in material and production time. The chances of an excursion occurring during the production process is higher as the material under processing changes hands a number of times and even in a completely automated process non conformities may occur at any stage of processing.
So what is required is a better information system that allows us to monitor the material during and after the production process. When we have a system that is capable of recording and reporting all the metrics relevant to a production lot, the chances of detecting and preventing an excursion are increased. Employing an integrated system that can track material throughout the production process is very important. I2DS is a pioneer in design and application of such innovative and cutting edge information systems. 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 system is 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 | Jan 30, 2019 | Blogs
MES applications have long been viewed as an ideal solution for better management of production floors around the world. Their ability to support a wide range of complex production flows is widely recognized and accepted. But is that all? Or is MES software capable of more? This is a question worth considering in the current business environment. MES applications are becoming more collaborative in nature, just as businesses around the world are evolving, so are the software applications which support them.
Today we will consider one such example of how a collaborative MES solution impacts and potentially improves the Warehousing function. Traditionally warehousing activities are carried at both ends of a supply chain. For any manufacturer warehousing of raw material and finished goods is a common practice. The availability of raw materials affects the production process greatly, with the advent of JIT management, having raw material exactly when required is pivotal for success and smooth functioning of a factory/plant. Similarly, warehousing also plays an important role when the raw material is fully processed and becomes the final product or products, if finished goods produced, are not available when required the company faces potential losses which go beyond the economic value of a cancelled order, as the loss of goodwill and future business become imminent. Thus, warehousing becomes an important function, which needs to be proactive at both ends of the supply chain and enable smooth production and delivery, it also needs to be a collaborative function working hand-in-hand with Purchase, Production, Logistics and Sales functions.
So where does MES come into the picture? Well, MES applications have become much more versatile and are capable of working in tandem with ERP and MRP systems. Previously warehousing was a manual process, where goods were stacked on racks based on their item/part numbers, when required workers would manually procure these materials and fulfill the order, once an order was filled, the workers would enter the data in an ERP system, which would then place an order for the materials depending on the pre-set reorder point. However, as technological advances are made, traditional warehousing practices are becoming extinct, modern warehousing is an intelligent activity, which is far more efficient and productive. Modern warehousing is an intelligent activity, which reduces human intervention in most parts of the process, it uses robotic arms or mobile robotic devices to fill orders and collect/place material on racks. In some warehouses racks themselves are mobile and reach the worker filling the order with required material rather than the opposite.
Due to the higher degree of automation, intelligent enterprise applications are extracting data almost at the same instant as an order is filled or a material is stacked. MES applications then communicate with such enterprise applications and both extract raw material data and provide production data to the application. Thus MES basically collaborates with other intelligent systems to provide a real-time picture of the raw material stock to the production/operation managers and at the same time allows sales/logistics and warehousing functions to know the status of the WIP and finished goods from the production process. This sort of collaboration benefits the entire operation of the supply chain and allows for proactive management and faster response time. The MES also acts as a vehicle for improving overall efficiency of the warehousing operation as the information received from the production function allows for better material planning and implementation of practices line JIT and Lean management.
So when you are deciding to choose an MES application for your production unit, take some time and consider whether the MES you are considering has the collaborative capabilities mentioned above. The warehousing example mentioned above is just a small illustration of massive benefits which an intelligent MES application can offer. To end the discussion I would like to stress the fact that an MES application is more capable than what it is considered capable of, it is important to consider all its capabilities and functionalities before selecting the application.
by | Jan 30, 2019 | Blogs
Technology has drastically transformed the way manufacturing industry functions today; it has become the major differentiating factor and is helping the top companies maintain their competitive supremacy in the market. Technology has become a potent weapon for the Best-In-Class organizations and has helped them achieve monopolistic positions in their respective markets. Since the advent of mass customization and delayed differentiation, technology has been used very differently by different companies of the same industry. This means every process has become unique in a bid to achieve differentiation and technology is the main driver behind this subtle differentiation. Thus whenever an organization is contemplating an increment in technology, it is important to consider the entire process as an individual entity, especially when considering an application like MES.
Operations management is also a pillar on which organizations build their competitive advantage. Operations management encompasses the entire organization, expertise in operations management can ensure that the process used by a particular organization remains the best in the industry. Operations Management in manufacturing industry revolves around the idea of managing the process by facts and doing things right the first time. Operations managers have moved from a fire fighting role to a planning role. QBD-Quality By Design, QFD-Quality Function Deployment, SPC-Statistical Process Control and Taguchi’s Quality Function are some of the theories and practices that advocate the involvement of Operations professionals in product planning, product design and process control.
Successful Organizations have realized the importance of Operations Management and Technology. These are the two factors that can make an ordinary operation a very efficient and successful one. An MES application combines both these facets of Operation; it is a combination of Information Technology and Operations Management. Manufacturing Organizations can benefit immensely by the application of MES application, as it provides both automation but also Integration of their entire production process under one comprehensive system. But choosing just any MES application can be very risky and lead to massive losses and develop a negative attitude in the workforce.
To be able to design the perfect MES application, expertise in both Technology and Ops Management are prerequisites. As I mentioned earlier, every manufacturing process has some unique attributes, an MES provider should be able to assess these unique feature and use them in the MES application so as to further benefit the customer’s Organization. I2DS is one such company that can boast of expertise in both Information Technology and Operations Management. The team of experts at I2DS has worked for few of the top organizations world wide and is renowned for its skills in Factory Automation, Information Technology, Data Management and Operation Management. This means that the team does not take any manufacturing process for granted, each process is carefully analyzed to determine the scope and functionality of an MES application.
I2DS brings more to the table than any other MES application provider in the industry. Every MES solution provided is tailor made to suit the present and future technology of the client, with the main aim of making Operation Management more efficient and decision making more concrete. If you also value Technology and Operations Management and believe that your MES application should facilitate these factors, I2DS is the best partner for you. To know more about our solution or to get your process analyzed by our panel of experts, e-mail us at info@i2ds.com or hit the Request Live Demo tab on this webpage and we will get back to you
by | Jan 30, 2019 | Blogs
TQM, Lean, Lean-Six-Sigma and Six Sigma are various theories of Operations Management or management on the whole that are helping organizations become more efficient and profitable around the world. I believe that these theories or management philosophies have a lot in common and should be pursued in spirit. We should try and understand the end goal of these theories rather than trying to implement them blindly without proper consideration. These theories should be treated more like guidelines rather than a set of rules or do’s and don’ts. What all these theories tend to stress on is the reduction of operational costs, increase of throughput, attention to Quality, better relationships and involvement of customers, employees and suppliers and above all the pursuit of sustainable profitability.
These theories lay emphasis on understanding the external environment and internal capabilities and achieving a dynamic equilibrium between the two. The approach to achieving this end goal is different in different theories, but the goal is the same. One major pointer that is emphasized in all modern management theories is that management should be fact based, that management decisions must be based on hard evidence and not managerial whims and fancies. The fact based approach brings me to the topic of my blog, which is implementation of management practices through IT applications.
IT applications can prove to be an effective way to apply and practice management theories. The beauty of such IT applications is that they can be tailor made for your process, which makes it easier for the staff to implement and can help improve the operations in the future. Depending upon the industry, IT applications can be programmed to monitor all vital process metrics, analyze the process performance, impart training, aid communication, facilitate supply chain integration, control production, improve safety, achieve quality excellence and the list can practically go on for ever. We need to understand that IT applications are not and elixir to our problems but are tools that can help us better resolve existing problems that we face on a day-to-day basis.
The idea is to implement IT applications in such a way that they facilitate real-time, fact based and potent decision making at all three levels of decision making i.e. at the Strategic level, Tactical level and at the Operational level. The design of the IT application should be such that it can suffice the decision making needs at all three levels and yet be comprehensive in its reach throughout the Organization. IT can help any organization and at any desired level of management, the need and scope of IT applications remain debatable and are best analyzed when considered for a particular process. My agenda here is to highlight that IT is a great tool because of its speed, agility and accuracy and should be given a consideration by all Organizations who are in pursuit of Operational Excellence and Profitability. I do not believe in following any management theory blindly without understanding its possible outcomes and neither do I promote blind faith in IT as an ultimate cure for all management problems.
I believe it is important to understand what your business needs to achieve the goal it has set for itself, besides the obvious goal of profit maximization. I strongly advocate fact based management and believe the IT applications can help achieve better results in a faster more organized manner. However, it is very important that before jumping to a so called IT solution we analyze our needs both external and internal, we understand the problem areas or pain points and then decide how and to what extent an IT platform can help appease our needs. I would like to conclude by reemphasizing a few pointers that I believe should be a part of any endeavor made towards improving management and improving profitability, they are, never choose a management practice blindly, use management practices as guidelines, try and improve profitability and quality and above all consider IT as a vital tool available to achieve your goals.
