Preserving Tribal Knowledge is no longer a daunting task. With HQ Designer your staff will be able to rapidly document Standard Operating Procedure's (SOP) in the format of Digital Work Instructions. In a matter of minutes, new Units can be created and deployed.
Built-In Photo Editing Tools
With HQ Designer, your staff can easily and swiftly upload and edit photos, streamlining the process of adding markups or including additional pictures and videos to the Work Instructions. There's no need to use multiple programs to aid in documentation, as HQ Designer provides a user-friendly and all-in-one platform for managing and enhancing your production processes.
Easier to Understand
Digital Work Instructions offer a significant advantage over traditional top-level Bill of Materials (BOM) and lengthy lists of required Tools. With Digital Work Instructions, you can display precise Text and Materials needed at each specific task, providing your Operators with clear and concise guidance at every step of the production process.
One remarkable feature is that Text can be written in English, and Compass can automatically translate it into the native language of your Operators. This translation capability ensures that all team members can access the instructions in their preferred language, eliminating language barriers and promoting better understanding and communication on the production floor.
The goal is not to simply preserve the methods of production processes, but to maximize the benefits of the labor invested in doing so. Digital Work Instructions can become Intelligent by implementing in-line Quality Assurance. Verify measurements, track serial numbers, mandate Inspector sign-offs, or require a "PASS" signal from test equipment.
By tailoring the the exact task at hand to satisfy your needs, Digital Work Instructions enable your Operators to focus on the relevant details, reducing the chances of errors and improving overall work efficiency. This personalized approach to instruction delivery enhances the user experience and facilitates smoother and more productive production runs.
A major question all manufacturers have when considering new technology is, "Will this work for us?" Rather than forcing manufacturers to alter their process to fit our software, we built it to be malleable to fit virtually any type of operation. With Customers around the world, from startup to international organization, we are confident our offering will align with your needs.
By the Numbers: Customers
Though we serve the Aerospace, Automotive, Rail, Consumer Goods, Food and Beverage, and Electronics Industries, all Customers share the same thing in common:
The desire to improve efficiencies of their operation
If becoming more efficient is important to you, then our service will be beneficial.
Since most of our Customers are vertically integrated, the specific type of usage is best reviewed by looking at where Compass Stations are deployed.
- 50% - Manual Assembly
- 35% - Fabrication Equipment
- 10% - Extrusion Equipment
- 5% - Robotic Cells
Understanding the Needs of the Station
At Scout Systems, we believe in tailoring our platform to meet the specific needs of each Work Area and Station in your manufacturing facility. This flexibility allows us to offer a comprehensive plant management software, eliminating the need for multiple vendors.
With our Accelerator Program, we dedicate the first month to thoroughly understanding your organization, production processes, and unique requirements. This ensures that we create a customized plan to propel your factory towards success. Together, we'll streamline your operations and achieve outstanding results.
We are committed to providing the best support for all our customers, regardless of their experience level. If you come across any unfamiliar terms while exploring our website, don't worry! We've got you covered with our handy glossary below. It contains definitions for all the technical jargon and terms, ensuring a smooth and clear understanding of our products and services.
Andon is an essential system in manufacturing that allows workers to promptly alert team members and management about quality or process issues. This is typically achieved by activating a light on a signboard that specifies which workstation has either observed a quality issue or is facing operational difficulties. In digital factories this is often done with dashboards.
The term Andon originates from Japan, and its meaning is roughly translated as "lantern." This is because the system functions like a lantern, highlighting issues on the production line as soon as workers detect them. By doing so, companies can quickly respond to problems and frequently pursue continuous improvement. Andon is crucial for ensuring quality control and promoting operational efficiency in manufacturing.
Application Programming Interface (API)
An API, or Application Programming Interface, is a set of protocols, routines, and tools for building software applications. It specifies how software components should interact and communicate with each other, allowing different systems or applications to share data and functionality. Essentially, an API acts as an intermediary between two applications, allowing them to communicate and interact with each other.
A batch refers to a specific quantity of a product that is produced in a single production run. The size of a batch can vary depending on the product being manufactured and the equipment used. For example, in the pharmaceutical industry, a batch may refer to a specific quantity of a medication produced using the same equipment and processes, with the goal of ensuring consistency and quality control. Batch production is often used in contrast to continuous production, which involves the ongoing production of a product without interruption or the need to stop and start production runs.
Bill of Materials (BOM)
A bill of materials (BOM) is a comprehensive list of all the raw materials, components, and sub-assemblies needed to manufacture a finished product. It includes all the information required to purchase, produce, and assemble the required parts, such as item names, descriptions, part numbers, quantities, and unit of measure. The BOM is an essential document for the manufacturing process, as it provides a detailed plan for the procurement and assembly of components, ensuring that the finished product is manufactured correctly and to the required specifications.
Cross-training is the practice of training employees in multiple job roles or functions within an organization. It is a process of teaching an employee additional skills, knowledge, and competencies beyond their current job description or position. The purpose of cross-training is to increase the flexibility of the workforce, improve employee morale, reduce the risk of a single point of failure, and provide career development opportunities to employees. By cross-training employees, they can take on new roles during absences or peak production periods, which can ultimately lead to increased productivity and efficiency.
Cycle time refers to the total amount of time it takes to complete a single production cycle or process, from start to finish. It includes all the steps involved in the process, including processing, waiting, inspection, and transportation times. It is often used as a performance metric in manufacturing to assess the efficiency of a production process and identify areas where improvements can be made to increase output and reduce costs.
A digital twin is a virtual replica of a physical object, system, or process that is used to simulate, monitor, analyze, and optimize its real-world counterpart. Digital twins are created by combining data from sensors, machines, and other sources to create a virtual model that can be used to simulate the behavior of the physical object or process in a digital environment. This enables users to analyze and optimize the performance of the physical object or process in real-time, and to predict and prevent potential issues before they occur. Digital twins are used in a wide range of industries, including manufacturing, healthcare, and transportation.
Downtime refers to the period of time when a machine or equipment is not operational or not performing its intended function. Downtime can be planned or unplanned, and it can result from various causes, including maintenance, repair, tooling changes, material shortages, and equipment failure. Downtime can have a significant impact on productivity, production schedules, and delivery timelines. Reducing downtime is a key goal of many manufacturing companies, as it can help improve efficiency, reduce costs, and increase profitability.
Enterprise Resource Planning (ERP)
An ERP is a type of business management software that allows organizations to manage and automate their core business processes in real-time. ERP systems integrate various departments and functions, such as finance, human resources, procurement, inventory management, and customer relationship management, into a single unified system. This helps organizations to streamline their operations, improve productivity, reduce costs, and enhance decision-making capabilities.
Gap analysis is a technique used to identify the difference or gap between the current state and the desired or expected state of a business or organization. It is often used as a tool for organizational change or improvement by identifying areas where a company is falling short of its goals or standards. Gap analysis involves comparing current business processes, performance metrics, and strategies to the desired future state, and then identifying what needs to be done to bridge the gap.
High-Mix Low-Volume (HMLV)
High-mix low-volume (HMLV) refers to a manufacturing production process that produces a wide range of customized products in low volumes. HMLV manufacturing is often used to produce a range of different products to meet the varied needs of customers, rather than producing a large volume of a single standardized product. This type of manufacturing can be more complex and costly than producing a single product in high volume, but it allows companies to offer a broader range of products and respond more quickly to changing customer demands.
Internet of Things (IoT)
The Internet of Things (IoT) refers to a network of physical objects, devices, vehicles, buildings, and other items that are embedded with sensors, software, and network connectivity, allowing them to collect and exchange data with each other and with other computer systems over the internet. This enables the objects to be monitored, controlled, and optimized in real-time, creating new opportunities for automation, efficiency, and innovation in a wide range of industries, including manufacturing, transportation, healthcare, and more.
Just-in-time (JIT) is a manufacturing philosophy that aims to produce and deliver products just in time to meet customer demand, with minimal inventory on hand. JIT systems strive to improve efficiency and reduce waste by streamlining the production process, minimizing inventory holding costs, and improving overall quality. JIT systems typically rely on close collaboration between suppliers and manufacturers to ensure that raw materials and parts are delivered exactly when needed, and in the required quantities, to support a continuous production flow.
Key Performance Indicator (KPI)
Key performance indicator (KPI) is a measurable value that demonstrates how effectively a company is achieving its key business objectives. KPIs are used to evaluate the success of an organization or of a particular activity in which it engages. Examples of KPIs might include financial metrics such as revenue growth, profit margins, or return on investment, or operational metrics such as customer satisfaction, on-time delivery, or defect rates. KPIs can help businesses identify areas of improvement, make informed decisions, and track progress over time.
In manufacturing and supply chain management, lead time refers to the time it takes to fulfill a customer order or to procure raw materials, components or subassemblies needed for production. It encompasses the entire process from placing an order, to processing it, to manufacturing and finally delivering the product. Lead time can vary depending on factors such as the complexity of the product, the availability of raw materials, the manufacturing process, and transportation times. Shorter lead times can lead to higher customer satisfaction and increased operational efficiency.
Lean manufacturing is a methodology that aims to reduce waste and increase efficiency in manufacturing processes. It originated in Japan and is also known as the Toyota Production System. The focus of lean manufacturing is to eliminate any steps or activities that do not add value to the final product or service, known as waste. This includes overproduction, waiting, excess inventory, unnecessary transportation, overprocessing, defects, and unused employee creativity. By reducing waste and focusing on continuous improvement, lean manufacturing aims to increase efficiency, reduce costs, and improve product quality.
Manufacturing Execution System (MES)
A Manufacturing Execution System (MES) is a computerized system that is used in manufacturing to manage and monitor work on the factory floor. It provides real-time data on the production process, allowing manufacturers to monitor and control production in real-time. MES software can track machine downtime, production rates, and other critical factors to help managers make informed decisions. It can also provide detailed production reports and analytics to help manufacturers identify areas for improvement and optimize production processes.
Overall Equipment Effectiveness (OEE)
Overall Equipment Effectiveness (OEE) is a metric used in manufacturing to measure the efficiency and productivity of equipment and machinery. It is calculated by multiplying the availability, performance, and quality rates of the equipment. The availability rate measures the percentage of time that the equipment is available for use, the performance rate measures the speed of the equipment, and the quality rate measures the percentage of products produced that meet the required quality standards. OEE is used to identify areas for improvement in the production process and to increase the productivity of the equipment.
Pareto, also known as the 80/20 rule or the Pareto Principle, is a concept in economics and business management that states roughly 80% of effects come from 20% of causes. It suggests that a small number of factors have a disproportionate impact on outcomes. The principle is named after Italian economist Vilfredo Pareto, who observed that 80% of Italy's land was owned by 20% of the population. The Pareto principle has been applied to a variety of fields, including manufacturing, quality control, and project management.
Poka-yoke is a Japanese term used in manufacturing that means "mistake-proofing" or "error-proofing". It refers to any mechanism or technique used to prevent errors or mistakes from occurring in a production process. The goal of poka-yoke is to eliminate defects by preventing, correcting or drawing attention to human errors as they occur. This can include simple physical devices or more complex systems and procedures that detect and prevent errors from happening. The aim of poka-yoke is to improve product quality and reduce waste, defects and costs in manufacturing processes.
Root Cause Analysis (RCA)
Root Cause Analysis (RCA) is a problem-solving technique that is used to identify the underlying cause of a problem or incident, rather than just treating the symptoms. The goal of RCA is to find the root cause of a problem so that it can be effectively addressed and prevented from recurring in the future. The process involves investigating the event, gathering data, analyzing the data, identifying the cause, and implementing corrective actions. RCA is commonly used in various industries, including manufacturing, healthcare, and information technology.
Six Sigma is a data-driven methodology and philosophy for achieving quality improvement in any process, product, or service. It involves the use of statistical methods and tools to identify and eliminate defects and minimize variability in processes. The goal of Six Sigma is to achieve a process that produces outputs with no more than 3.4 defects per million opportunities (DPMO). The methodology is organized into five phases: Define, Measure, Analyze, Improve, and Control (DMAIC) and it is widely used in industries such as manufacturing, healthcare, and finance.
Software as a Service (SaaS)
Software as a Service (SaaS) is a software delivery model in which the software application is hosted by a third-party provider and made available to customers over the internet. In this model, users typically pay a subscription fee to access and use the software, rather than purchasing and installing it on their own computers or servers. SaaS can be used for a variety of applications, such as customer relationship management (CRM), enterprise resource planning (ERP), and human resources management (HRM).
Standard Operating Procedure (SOP)
Standard Operating Procedures (SOPs) are step-by-step instructions that outline the procedures or processes required to complete a particular task or activity. They are often used in manufacturing, healthcare, and other industries to ensure that processes are completed consistently and safely. SOPs provide detailed guidance on how to carry out specific activities, including any necessary precautions, and can help to minimize errors, reduce variability, and increase efficiency.
Takt time is a term used in lean manufacturing and refers to the available production time divided by the customer demand for a product or service. It is essentially the rate at which products need to be produced to satisfy customer demand while also optimizing production efficiency. By calculating the takt time, manufacturers can adjust production to meet customer needs in a timely and efficient manner.
Tribal knowledge refers to information and knowledge that is not documented or shared in a formal way within an organization, but is instead passed down informally through conversation, observation, and experience. It is often based on the collective knowledge and experience of a group of individuals who have been with the organization for an extended period of time, and may include tips, tricks, and best practices for getting things done. However, because tribal knowledge is not documented or shared in a formal way, it can be difficult to transfer to new employees or to scale up operations.
Waste refers to the amount of material, energy, or resources that are discarded or lost during the production process. This waste can take many forms, including defective products, excess raw materials, scrap, rework, and wasted time. Reducing production waste is an important goal for many manufacturers, as it can lead to cost savings, improved efficiency, and reduced environmental impact.
One of the most challenging elements of Continuous Improvements is to know what processes need updating. When something is clearly broken, finding solutions becomes more straightforward. However, in analog factories, discovering problems is a laborious, slow, and isolated process, limited to what is manually reviewed. On the other hand, digital factories, particularly those using Scout Systems, have a significant advantage, as their problems are easily highlighted and readily visible. This advantage accelerates the path to improvement, leading to more efficient and effective manufacturing operations.
Role Based Production Reports
Scout Systems leverages a powerful combination of Industry Standards and Lean Six Sigma methodology to thoroughly analyze production data, offering an array of four distinct report categories.
Unit Reports are a helpful tool often utilized by staff responsible for reviewing billable times or managing production scheduling. These reports offer valuable information related to the average labor required for building your product, and they also enable a close examination of specific details by zooming into individual Serial Numbers.
Station Reports are a powerful resource frequently employed by Manufacturing Engineers and Operations Management. These reports are designed to delve into the performance of a specific station, providing valuable insights such as hourly throughput, labor distribution, effectiveness, and a comprehensive overview of the staff that worked in that station.
Operator Reports are a valuable asset for Workforce Management, frequently utilized by Leads and Production Supervisors. These reports allow you to assess the productivity of each operator across all station types, enabling you to identify training opportunities and address any areas that need improvement. Additionally, Operator Reports help you track an operator's activity throughout their shift, pinpointing any recurring issues that may arise. Furthermore, these reports provide valuable insights into the reasons behind production stops, empowering you to make informed decisions and enhance overall production efficiency.
Machine Reports are a vital resource for Maintenance and Manufacturing Engineers, serving as a powerful tool to optimize equipment utilization and enhance overall value. By utilizing these reports, your staff can gain valuable insights into operator performance when building similar products, helping to identify any significant variations in production metrics. Additionally, Machine Reports enable you to record and implement the best setup techniques, further improving equipment efficiency and reducing downtime.
Your Strategic Partner
Scout System's Accelerator Program offers a refreshing approach, ensuring that you receive only the data you need without overwhelming your team. With the guidance of a dedicated Customer Success Representative, your staff will be educated on the most relevant Reports to support your organizational goals. No more analysis paralysis – we'll teach you how to digest and utilize the information effectively. In just 3 months, your company can undergo a digital transformation, positioning itself for significant improvement and success. Say goodbye to data overload and hello to streamlined, actionable insights!
Staying ahead of the competition requires a proactive approach to managing your factory operations. With Scout System's advanced solution, manufactures now have a digital twin of their factory to allow for better monitoring and control of their production processes like never before.
Real-Time Production Dashboards
Gone are the days of relying solely on static reports or periodic updates. With Scout Systems, management staff can access real-time production dashboards that provide live, dynamic insights into every aspect of the production floor.
Emails, calls, or floor walks are no longer needed to learn of progress reports of active orders. Instead, they will be able to access interactive dashboards using their cell phones or computers from anywhere in the world.
Improved Workforce Management
Tribal Knowledge extends beyond just the Production Floor Staff. Leads and Supervisors often possess invaluable insights into their Operator's unique strengths and areas for improvement, making this knowledge a valuable asset for the company.
By leveraging Scout Systems, you can capture and preserve the abilities of your Operators in a structured and accessible manner. Through detailed Production Reports, you'll gain valuable insights into training opportunities that can be harnessed to maximize the potential of your Operators.
Your Management will be able to analyze high-volume products and identify Operators who consistently maintain the fastest paces, uncovering hidden talents and abilities. By identifying these skilled Operators, you can pinpoint valuable Tribal Knowledge that needs to be documented and preserved.
With this data-driven approach, you'll enhance your team's performance and ensure that critical expertise is captured for future success.
With Scout Systems' cloud-based application, your Management gains the convenience of 24/7 access to your factory's data from anywhere in the world. Whether tackling night shift complications or troubleshooting while on the go, your factory's critical information will be readily available at their fingertips, ensuring seamless decision-making.
Leveraging the wealth of exceptional data collected and processed by Scout Systems, you can integrate it with your ERP to create custom dashboards and reports tailored to your organization's specific focus points. This powerful combination empowers your Management team to excel in their roles, providing them with valuable insights and enabling them to make informed decisions with confidence. With real-time access to relevant data, your Management will drive your factory towards even greater efficiency and success.
Establish this in only 3 Months
Unlock the full potential of your factory in just 3 months with the Scout System's Accelerator Program. Our platform will be expertly tailored to your company's needs and seamlessly deployed, ready for full operation. Say goodbye to the delays and inaccuracies of traditional decision-making methods and embrace the power of the digital era. With our platform, your entire staff, from Operators to Management, will elevate their performance to new heights. Don't wait any longer; take the leap into the future of manufacturing with Scout Systems.
Meeting customer demands for higher quality and lower costs can be a daunting task, especially with manual processes. Traditionally, improving quality meant investing more in labor, conducting numerous visual inspections, additional tests, and extensive training efforts. However, the good news is that technology has finally caught up, offering a game-changing solution to reduce the cost of quality.
Integrating Equipment with Instructions
With Intelligent Work Instructions, you have the power to define specific requirements in the physical world, ensuring that the process proceeds only when these requirements are met. Whether it's Smart Tools, Test Equipment, Machinery, or fixtures & jigs, you can integrate them seamlessly into your workflow. This eliminates the need for extra labor to validate the process, as everything can now be automated.
Tracker, our near-universal signal interpreter, is designed to seamlessly connect with a wide range of equipment, thanks to its ability to read various signal types. With this versatility, integrating Tracker with your existing machinery becomes a breeze. You won't have to worry about firmware updates, as the edge device is built to be self-sufficient, eliminating any potential hassles. Moreover, its rugged construction ensures that it can withstand the demands of even the harshest manufacturing environments.
After successful installation, you can log into Compass as a Technician to set up and configure the parameters of the connected physical equipment.
When crafting Work Instructions for Station Types with linked equipment, you gain access to the powerful Validations feature. This enables HQ Designer to recognize the connected equipment and empowers you to set specific signal requirements. With Validations engaged, you can ensure that your instructions align perfectly with the equipment, resulting in more accurate and efficient operations. Embrace this functionality to elevate your production process and enhance quality control.
A New Era of Quality Assurance
As your factory embraces digital connectivity, you'll discover exciting possibilities to cut down on your cost of quality. By integrating Digital Work Instructions, particularly those with physical signals, you can automate quality checkpoints and significantly reduce the labor involved in reviewing your Operator's work.
Leveraging our Application Programming Interface (API) Portal, you can seamlessly connect your production data to your Quality Management System, eliminating manual data entry and the potential for human error.
Boost Customer Confidence with Innovation
Discover the power of Scout System's Accelerator Program, the express lane to modern innovation that leaves a lasting impression on your customers. In just 3 months, your factory can experience remarkable progress in implementing error-proofed production cells. With an impressive success rate of over 90%, we are certain that by the end of the program, you'll be more than confident in the capabilities of our product and the unwavering support we provide. Don't miss this opportunity to revolutionize your manufacturing process and exceed your customers' expectations.
In the dynamic world of manufacturing, Time Studies stand as the bedrock for estimating costs and predicting schedules, providing crucial baseline data for informed decision-making. Without this essential foundation, manufacturers are left to navigate the uncertain waters of guesswork, which can lead to costly errors, such as under-bidding or excessive overtime, resulting in lower profits.
Traditional methods of Time Studies rely on manual labor, with observers using stopwatches and clipboards to track production runs. While adequate in the past, these methods have their limitations and can be costly. As your manufacturing processes evolve, historical data becomes obsolete, necessitating the need to redo Time Studies—a burden for manufacturers already struggling to find skilled labor.
Instantly Collect All Data
Recognizing the paramount importance of 100% Time Studies, Scout System's platform has been meticulously designed for effortless deployment, empowering customers to record every production order with ease. Unlike traditional methods that demand product documentation beforehand, our platform allows Operators to create jobs for new, or previously undocumented units.
Once an Operator initiates a job for an unknown unit, the platform confirms their intent, and upon approval, switches to the user-friendly Instruction-Less mode. This streamlined state provides Operators with the same production support access while thoroughly collecting all production data in real-time, ensuring accurate insights for informed decision-making.
There are many benefits of Instruction-Less mode, including:
- Lower Project Labor Cost
- Simplified Operator Training
- Work Instructions can be Created at Your Pace
- Collect Data on Process that do not need Instructions
Automate Data Processing
One drawback of 100% Time Studies is the possibility of flawed data collection. Operators might get distracted or pulled away from a task, resulting in a failure to press Pause accurately. However, human error is natural and unavoidable. Scout Systems addresses this by carefully analyzing every data point and identifying abnormalities.
When the platform identifies a dataset as erroneous, it will be excluded from certain production reports. In the given example above, the system recorded 24 products built, but it detected two questionable datasets (shown as 23). Rest assured, the data is not deleted. If the irregular dataset recurs, the platform will adapt and recognize it as a regular part of operations, no longer being considered questionable.
With this advanced data processing, your Engineers will be freed from unnecessary statistical work, allowing them to focus on more critical tasks. This level of automation provides you with the utmost confidence in your reports, ensuring accurate and reliable production data for better decision-making.
Data Adaptation to Change
Continuous improvement is a regular occurrence in manufacturing, and significant changes can render historical production data inaccurate. However, with Scout Systems, you won't have to burden your staff with identifying these change moments and updating production goals manually.
Not only does the platform detect questionable data, but it also identifies repeatable high-performance metrics. Our "Performance" score is derived from the fastest repeatable production runs with high quality, and it plays a crucial role in calculating the Overall Station's Effectiveness (OSE). With this automated process, you can confidently implement Process Changes without worrying about manually updating your performance goals.
The Easiest Way to Evolve
The advantages of digitizing a factory are limitless, and the good news is that technology costs have significantly reduced, making it affordable for organizations of all sizes. Scout System's Accelerator Program is a comprehensive fixed-cost, 3-month initiative designed to address your challenges and implement a digital platform seamlessly. Unlike a typical trial, this program propels your organization into the digital era, and by the end, you'll have the assurance that Scout Systems is not only the perfect technology fit but also an invaluable strategic partner in your continued growth. Get ready for a transformation that will unlock your factory's full potential!
Intelligent Work Instructions represent a significant leap forward in the evolution of Standard Operating Procedures. The advancements in this field are truly remarkable. Gone are the days of Engineering Prints and paper-based instructions in binders, or even PDF versions displayed on digital screens. These traditional methods lack intelligence, often rely on the expertise of individual operators, are prone to human error, and fail to capture valuable production data.
The adoption of Intelligent Work Instructions brings about transformative benefits, including:
- Reduced Training Time
With intelligent instructions, the learning curve is greatly shortened. Operators can quickly grasp complex processes and procedures, leading to faster onboarding and increased productivity.
- Lower Cost of Quality
By providing precise and error-proof instructions, intelligent work instructions minimize costly errors and rework. This translates to significant savings in terms of time, resources, and overall quality control.
- Increased Production Capacity
Intelligent work instructions optimize workflow and eliminate bottlenecks. By streamlining operations and ensuring consistent execution, production capacity can be enhanced, leading to higher output and improved efficiency.
Embracing Intelligent Work Instructions unlocks a world of possibilities for manufacturers, empowering them to achieve operational excellence, enhance training processes, and drive overall productivity.
Reducing Training Time
Clear instructions play a crucial role in accelerating operator training. At Scout Systems, our customers consistently experience a remarkable reduction of nearly two-thirds in the time it takes for new operators to reach the productivity level of seasoned veterans. Let's take a closer look at an example that illustrates this progress:
In the case above, the operator was able to achieve the pace of a veteran and maintain it by the 9th unit built. This remarkable progress demonstrates the effectiveness of our clear and comprehensive instructions in expediting the learning process.
What leads to this Rapid Training?
Accelerating training is essential for boosting productivity and efficiency in your operations. Let's dive right in and explore the key benefits of our training offerings:
Better Organization: Our platform provides a centralized location for all production information, making it quick and easy to access and understand what work needs to be done. No more searching through multiple sources or documents.
Clear Setup Instructions: Operators can instantly view the tools, materials, and setup requirements for each work order, ensuring a smooth and efficient preparation process. Our instructions leave no room for confusion.
Step-by-Step Work Instructions: Each task is presented in a clear and concise manner, with visual callouts and accompanying text. For more detailed guidance, we even offer the option to embed instructional videos, providing a comprehensive learning experience.
In-Line Quality Checks: Our platform empowers operators to perform in-line quality checks, verifying parts, validating dimensions, and capturing pictures of work in progress. This ensures that quality standards are met and maintained throughout the production process.
Call for Help: With just a simple button press, operators can request assistance when needed. Leads and supervisors can monitor operator activities remotely and receive real-time notifications if any delays or issues arise, enabling timely intervention and support.
Lowering the Cost of Quality
Traditional methods of improving Quality can often come with increased costs. This is because most Quality improvements include more inspections, more data collection, and more data entry. A huge benefit of Intelligent Work Instructions is that all of those methods and others can become automated.
New forms of Automation
Revision Control: Say goodbye to the hassle of managing and updating multiple versions of your work instructions. With our platform, every time an update is made, all versions accessible to the production floor will automatically be updated to the most recent release. No more searching for and updating outdated prints. Stay organized and ensure everyone has access to the latest instructions.
Test Integration: Seamlessly connect your test equipment to our platform and streamline the testing process. Operators can validate passing test results directly within Compass, eliminating the need for manual documentation or buddy checks. Our system ensures that operators cannot proceed unless they receive a passing signal, enhancing efficiency and accuracy.
Data Integration: Harness the power of your production data with our seamless data integration capabilities. All production data is collected and processed, providing valuable insights for analysis and decision-making. Utilize our APIs to effortlessly send data to third-party platforms, eliminating the need for manual review of data tables and tedious result updates. Unlock the potential of your data and leverage it to drive improvements and optimize your operations.
Increasing your Production Capacity
There are multiple strategies you can employ to increase your production capacity, tailored to the specific nature of your factory operations. These strategies can be broadly categorized into two approaches: reducing waste and improving efficiency.
A common method of reducing waste is to measure production stops so that changes can be deployed to reduce.
When production stops occur, your operators can easily record the downtime by pressing the 'PAUSE' button within Compass. The system will promptly begin to track and record the precise time lost during the stoppage.
To delve deeper into the root issues behind production stops, you have the option to create Root Cause problems. These problems can be associated with specific production stoppages and help identify the underlying reasons for the interruptions. By pinpointing the root causes, you can implement targeted solutions to minimize or eliminate similar issues in the future.
Discovering Hidden Waste
Waste can take various forms and may not always be apparent with traditional tracking systems. With Scout Systems, you gain a remarkable advantage as every action is meticulously recorded and analyzed throughout each production order.
This level of detailed tracking allows you to zoom into your cycle times, providing valuable insights into your production process. By examining the data, you can pinpoint specific steps that may be causing delays or inefficiencies, helping you identify opportunities for improvement.
In the example above, we are analyzing the individual step times required to build a product. The blue bars represent the Average Time taken for each step, providing a clear understanding of the typical duration for each task. Alongside the blue bars, gray lines overlay to illustrate the Standard Deviation.
The Standard Deviation is a crucial metric that reveals the variability or spread of data around the average. In this context, it indicates how much your operators deviate from the average time taken for each step. A larger Standard Deviation suggests that your operators struggle to maintain a consistent pace, leading to more significant variations in their performance.
Identifying steps with larger Standard Deviations can be instrumental in pinpointing areas where operators may encounter challenges or inefficiencies. By focusing on these steps, you can provide targeted support, training, or process improvements to help your operators achieve a more consistent and efficient workflow.
Though reducing Waste often leads to improved efficiencies, utilizing Intelligent Work Instructions can provide even more opportunities to benefit from.
Enabling your Production Supervisors with access to real-time Production Key Performance Indicators (KPIs) is a game-changer in making informed decisions to enhance production flow. Among the most critical metrics is Overall Equipment Effectiveness (OEE), which provides a comprehensive assessment of equipment performance and utilization.
What sets Scout Systems apart from other SaaS offerings is our unique implementation of OEE even in non-equipment cells. In our Reports, we refer to it as Overall Station Effectiveness (OSE), reflecting its applicability and value across various production areas beyond traditional equipment-centric metrics.
Overall Station Effectiveness (OSE) is a powerful metric calculated by considering three key factors: Performance (speed of production), Availability (time working compared to total time), and Quality (ratio of good parts to total parts). By multiplying these three factors, Scout Systems generates the OSE value, providing a comprehensive and accurate assessment of the station's efficiency and effectiveness.
The continuous data collection and analysis in Scout Systems ensure that OSE is dynamically adjusted to reflect real-time efforts. This means that any changes or adjustments made in the production process are immediately reflected in the OSE metric. Your Production Supervisors can instantly see the positive or negative impacts of production adjustments, empowering them to make informed decisions and respond quickly to optimize productivity.
Get Caught up in only 90 Days
The benefits of adopting Intelligent Work Instructions are indeed significant, but we understand that implementing such a transformative change can feel overwhelming. That's where our Accelerator Program comes in – it's a personalized program designed to work closely with your staff to ensure a smooth and efficient implementation of this evolution.
With the Accelerator Program, Scout Systems' experts will be by your side every step of the way. We will collaborate closely with your team, providing hands-on support to guide you through the entire process. Our focus will be on delivering the specific outcomes you've set for your organization, tailoring the implementation to meet your unique needs and goals.
By partnering with Scout Systems in the Accelerator Program, you gain access to our wealth of experience and expertise in the field. We understand the challenges and opportunities associated with adopting Intelligent Work Instructions, and we are dedicated to making the transition as seamless as possible.
Rush jobs often compel production cells to abruptly shift gears, causing substantial waste. The time spent on setting up for a new job and the increased risk of damage to work-in-progress (WIP) due to potential mishandling can strain your resources considerably. Additionally, the hurried pace heightens the likelihood of your Operators overlooking crucial steps, compromising quality. Addressing rush jobs goes beyond time management - it's about preserving process integrity and quality, while minimizing waste and maintaining productivity.
The Balancing Act of Rush Jobs
In an analog factory Production Supervisors have limited real-time information. This typically results in Rush Jobs taking precedence over active orders. Instead, imagine if your Production Supervisors could be accurately informed when the Rush Job would finish if they allowed the active orders to complete without disruption.
Manufacturers employing a Shop Floor Management system gain a notable edge in this situation. Advanced digital platforms, like Scout Systems, equip your staff with real-time data, offering predictive analysis on production order completion times. Leveraging such information can often reveal that pausing an ongoing job to accommodate a rush order may not be required. Therefore, digital integration into your manufacturing process not just optimizes efficiency but also arms your staff with insights for making informed, cost-effective decisions.
Halting and Resuming Production Orders
For jobs that must be halted due to reprioritization, your Operators will need to know if the last unit was completed or if it’s still a work in progress. If it wasn’t completed, what was the last task done? How many units remain for the order? Navigating the transition from completing a rush job back to the original production order can pose challenges, especially during a shift change.
Failing to clearly answer these questions will result in longer change over time and increased chances of defects. Digital work instructions fix this issue entirely. Your Operators simply press Suspend Job and move onto the rushed order. When they return to the suspended job, the platform returns them to the exact location the job was disrupted.
Improve On-Time Delivery in 90 Days
Transitioning to a digital factory has immense benefits, beyond assisting your factory when rushed. Scout System’s Accelerator Program is a custom tailored project where we work directly with you to implement our digital shop floor management platform. A dedicated Customer Success Representative will be assigned to your team and will help configure the technology to target your pressing challenges. In just 3 months customers discover increases in their capacity, reductions in their training time, and massive improvements to overall product quality. The majority of new customers achieve a return on their investment in a matter of months!
Every single shift of every single day will experience Operator Inactivity; it is a common phenomenon that significantly impacts your productivity. Generally, it falls into two distinct categories - Operator-induced Inactivity, derived from individual operator issues, and Operation-induced Inactivity, stemming from organizational shortcomings.
Operator-induced Inactivity arises when an operator's personal issues, lack of motivation, or distinct focus-lapse periods cause delays. Such instances can hinder your workflow and productivity significantly. Direct engagement of Leads and Supervisors is often the most effective strategy to overcome these issues. They can motivate and monitor operators closely, facilitating an environment that encourages productivity and consistent workflow.
Contrarily, Operation-induced Inactivity is tied to your institutional challenges such as weak training programs, a lack of necessary resources, or existing procedural inefficiencies. If your factory has not yet transitioned to digital, addressing these issues requires a thorough examination and scrutiny of production lines and processes. Once you identify the root cause(s), appropriate solutions can be implemented to minimize disruptions and ensure smooth operations.
In my experience, this process can be simplified by adopting the perspective of a brand new employee. Asking questions such as, "What am I supposed to build, and how do I do it?" helps discern underlying issues, paving the way towards developing effective strategies that promote efficiency and productivity.
The Scout Systems Advantage
A significant portion of Operation-induced Inactivity can be mitigated utilizing digital work instructions, a prime advantage offered by digitized factories. Your Operators can be equipped with detailed, interactive access to daily production schedules, coupled with visual representations that guide them through the required steps to construct your product correctly. Embedded videos provide a seamless solution to understand complex tasks, drastically reducing the need for offline training. These visual aids streamline learning, ensuring a more efficient, uninterrupted manufacturing process. It's a smart blend of technology and practicality, saving time and enhancing productivity.
Another standout feature of the digital factory is having the capability to closely track the pace of production. Imagine your improved production rhythm if your Operators received prompt notifications if their progress rates fall below the anticipated speed. In the event the process is still failing your Operators, they can request assistance simply by pressing a button. This seamless facilitation of immediate help significantly reduces downtime and enhances overall productivity.
Catch Up with Innovation in just 3 Months
The advantages of a digital factory are truly transformative, revolutionizing operational efficiency and aiding in overcoming most Operation-induced Inactivity issues. If you feel that you are ready to transition to a digital factory, know that it can be done quickly and with minimal efforts of your staff. Scout System’s Accelerator Program is a 90-day blitz launching the platform with a focus on solving your pressing problems. You will have a dedicated Customer Success Representative that will become a part of your team and provide expert guidance. Reach out for a free consultation to see how this technology can assist in your growth.