In a world where everyone wants more for less, the burden often falls on Manufacturers to prioritize new ideas to lead to greater cost saving opportunities.
Lean Manufacturing Principles
Lean manufacturing methods focus on efficiency, both in terms of processes and employee productivity and should be a core value in all organizations. Lean implementation stimulates the perfect balance between minimal waste and maximum output, leading to a drastic cut in operational costs and rapid ROIs.
Lean manufacturing methods provide a tangible competitive edge, optimizing operations for minimal waste, increased output, and superior product quality, thus enhancing customer satisfaction and retention.
In today's technologically advanced factories, lean manufacturing is revolutionizing operations. By encouraging continuous improvement and valorizing employee feedback, it enhances the production process, enabling assemblers and fabricators to impress customers with high-quality products and swift delivery times.
Implementing Just-In-Time (JIT) Inventory
Don't let potential cost savings slip through your fingers. Embrace Just-In-Time (JIT) inventory—a cost-effective technique revolutionizing assembly lines and proving instrumental to thwart threats of overproduction. Let's review its benefits.
- Substantial savings: Minimize overhead costs by ordering only what's necessary, and when it's needed.
- Increased efficiency: JIT systems streamline production by eliminating unnecessary inventory proliferation.
- Improved cash flow: By avoiding stockpiling, funds can be successfully funneled into other business growth areas.
- Enhanced supplier relationships: Regular, smaller orders pave way for maintaining consistent supplier interactions.
- Reduced waste: With JIT, you order inventory right when required, reducing chances of spoilage or outdated stock.
- Risk mitigation: Overproduction risks are rendered irrelevant because production happens based on real-time demand.
Reducing Waste with Six Sigma Methodology
In the drive to reduce waste and enhance profitability, Six Sigma methodology has outlined a systematic, data-driven approach that allows assemblers and fabricators to reach a new level of precision, consistency, and quality.
- Identifying and eliminating process variations with Six Sigma's DMAIC (Define, Measure, Analyze, Improve, Control) model
- Adopting quality management tools such as Pareto charts, fishbone diagrams, and process maps
- Creating a culture of continuous improvement, fostering employee engagement
- Minimizing material usage and scraps by optimizing processes
- Leveraging data analysis for predictive maintenance, avoiding breakdowns and delays
Streamlining Production Processes with Value Stream Mapping
Value Stream Mapping is a highly recommended method for uncovering inefficiencies in your production line, providing a clear road map for achieving greater efficiency. This pivotal tool will help fine-tune fabrication efforts while illuminating the areas where your assembly lines can be improved.
- Identifying issues in real-time: Value Stream Mapping helps audit problems in your manufacturing process as they occur, allowing you to take immediate actions.
- Minimizing waste: This method exposes redundancy and waste in your assembly line, enabling you to make necessary adjustments.
- Enhancing productivity: It provides an opportunity to optimize work processes and eliminate activities that do not add value.
- Promoting continuous improvement: This tool encourages a culture of routine upgrades, helping your assembly line stay on the cutting edge of efficiency.
In the past, automation in manufacturing was primarily focused on the use of physical equipment to streamline processes. However, with the advancements in technology, there are now multiple new opportunities to automate various aspects of manufacturing beyond just the physical realm.
One such area is data collection and analysis. By implementing digital software systems, you can automate the collection of data from different stages of the production process. This not only saves time but also ensures accuracy and consistency in data collection. Additionally, these systems can provide real-time analytics and insights, allowing you to make data-driven decisions and identify areas for improvement.
Another aspect that can be automated is the tracking of quality records. Instead of relying on manual record-keeping, digital software systems can automate the recording and tracking of quality data. This not only reduces the chances of errors but also provides a centralized and easily accessible repository for quality records. This automation can help streamline quality control processes and ensure compliance with industry standards.
Furthermore, automation can also help reduce or even eliminate the need for paper-based documentation. By digitizing processes and implementing electronic documentation systems, you can significantly reduce paper usage, storage costs, and the risk of document loss or damage. This not only contributes to cost savings but also aligns with sustainability initiatives.
Implementing Automated Quality Control Systems
High quality no longer needs a high labor cost to accomplish, by embedding Quality Control systems directly into digital work instructions. These systems allow you to dynamically adjust quality checkpoints to appear more or less frequent due to the specific problem - instead of relying on factory-wide generic guidelines.
By enabling real-time fault detection, you will experience a reduction of rework and instead increase your throughput rates. Eliminating manual errors, your production pace will accelerate and simultaneously ensure consistent product quality.
These systems offer assemblers a paradigm shift from traditional time-consuming quality checks to real-time precision. The resulting savings in manpower and resources are significant, making it an investment worth considering for modern manufacturers.
Energy Efficiency Strategies
Elevating energy efficiency distinguishes itself as a pivotal component for generating manufacturing savings. Incorporating efficient practices caters to both sustainability criteria and improved financial outcomes.
Seizing the potential of energy efficiency enables drastic cost reductions in the manufacturing industry. The conscious reconfiguration of processes towards energy optimization epitomizes a strategic approach for manufacturers.
Optimizing Equipment and Machine Settings for Energy Savings
Unlocking potential savings starts with machine optimization, focusing primarily on energy efficiency. Conscious calibration and setting adjustments on equipment can vastly decrease energy consumption, thereby reducing energy costs significantly.
Optimal equipment settings play a driving force, leading to major energy savings. These settings allow machinery to operate at peak efficiency, translating into decreased power usage. Ultimately, enterprises experience significant cost savings in the long term.
Investing in Energy-Efficient Machinery
The transformation to energy-efficient machines in manufacturing is financially viable. Initial expenses are offset by significant savings in energy consumption and maintenance costs in the long run.
A shift to energy-efficient machinery marks a pivotal moment in manufacturing. These systems not only reduce energy use but also improve productivity with less downtime.
This revolution has positioned manufacturers ahead of the curve. They're delivering better work while maintaining environmental integrity, giving them a competitive edge in today's eco-conscious business landscape.
Implementing LED Lighting Systems
Incorporating LED lighting systems can illuminate more than just your manufacturing spaces—it can brighten your profit margins. These systems, known for their energy efficiency, can significantly reduce your energy consumption and operational costs.
Switching to LED lighting is not just an ecological decision, it's financially smart. The long-term cost reduction associated with these systems greatly outweighs the upfront expenses, making it an ideal choice for cost-conscious assemblers and fabricators.
Supply Chain Optimization
Leveraging an intelligent supply chain doesn't only streamline the operations but also anchors cost reduction. Implementing smart supply chain practices like using predictive analytics, AI, and IoT can help manufacturers better predict demand, optimize inventory management, thereby reducing carrying costs.
Addressing potential gaps in supply chains can result in considerable savings. Implementing strategies such as vendor-managed inventory, advanced planning, and scheduling systems, companies can minimize delays, better manage their production schedules, and ultimately cut costs. Efficient supply chain operations are key in realizing cost reductions while maintaining high levels of product quality and customer satisfaction.
Establishing Strong Supplier Relationships
Strategic alignment with your suppliers elevates beyond mere transactional exchanges, enabling mutual value creation. Deepening these partnerships encourages joint problem-solving, innovation, and shared success, transforming your supply chain into a competitive advantage.
Investing in supplier relationships can result in significant cost savings. The mutual trust built through these bonds may speed up response times, reduce downtime, and ensure timely deliveries, easing fiscal tension.
Furthermore, a strong supplier bond not only ensures supply continuity but can also open doors for negotiation, offering favorable prices or payment terms. An excellent supplier relationship fosters financial resilience, operational efficiency, and strategic growth.
Implementing Vendor-Managed Inventory (VMI)
Have you explored Vendor-Managed Inventory (VMI)? VMI liberates manufacturers from inventory management, enabling seamless production and revenue maximization.
Recognize VMI as the unseen cost-saving hero in manufacturing. It significantly reduces procurement related costs, directly influencing your bottom line.
VMI offers a fresh perspective, shifting inventory management to suppliers. This approach curbs unexpected stockouts and enhances customer satisfaction.
Utilizing Advanced Planning and Scheduling (APS) Systems
Advanced Planning and Scheduling (APS) systems, when properly implemented, act as a smart strategy for manufacturing, offering substantial cost savings. Such systems streamline operations, minimizing downtime and wasteful procedures.
APS systems are precision tools that drive down manufacturing costs by deftly coordinating production activities. They allow for seamless scheduling, ensuring operations keep pace with demand and resources are optimally utilized.
In addition, APS systems provide real-time visibility into the manufacturing process. This ability to monitor activity enables quick adjustments, sidestepping potential bottlenecks and reducing costs associated with idle machinery or inventory.
The Importance of Process Control
Your customers do not want defects, and the best way to improve quality without eating into your profit margin is to improve your Process Control. This not only enhances productivity but also ensures consistency and accuracy in the manufacturing process.
Why is Work Instruction Software important?
Work Instruction Software offers several benefits for manufacturers. Firstly, it provides a centralized platform for creating, managing, and sharing work instructions. This eliminates the need for multiple tools like Word, Excel, or PowerPoint, streamlining the process and reducing the chances of errors or inconsistencies.
Secondly, Work Instruction Software allows for easy customization and standardization of work instructions. Manufacturers can create templates and standardized formats for different processes, ensuring that all operators follow the same visual guidelines. This not only improves efficiency but also reduces the time and effort required to develop new work instructions.
How to improve Revision Control?
Utilizing a Work Instruction Software will certainly assist you in standardizing your documentation and reduce the labor associated with this task, but as long as paper is used to display your instructions you will run into the risk of human error. With each revision made, you must locate and replace every instance of the previous instruction. A solution to this challenge is to digitize the display directly at the production cell. At the minimum, you could create a repository of PDFs which will allow your documentation control team a centralized location to update all revisions.
A better solution would be to implement a Work Instruction Software platform that has it's own digital viewer made specifically for the production employees. These types of viewers will allow more detailed instructions that could support multimedia elements. Manufacturers can leverage multiple engageable images, videos, or interactive elements to embed quality assurance methods. Not only does this help in maintaining consistency while avoiding confusion on the shop floor, it opens up a new world of data collection.
What are the Instant Benefits?
The goal of all change projects is to directly improve your bottom line, transitioning from analog systems and moving towards a virtual world will open new forms of automation. The most immediate benefit is the elimination of Time Studies, never again will you pay for the time to record production data, but instead every product built will automatically be tracked without any data entry. This valuable information will lead to more accurate billing, and a balanced production schedule.
Digital Work Instruction platforms can also be integrated in with other existing platforms, establishing the necessary foundation to eliminate the need of paper. Imagine the day your ERP can automatically broadcast the production cell, your operators are guided with rich media, and your Quality Assurance can be enforced with less labor.
What are the Potential Risks Associated with Digital Work Instructions?
Most software platforms are migrating to the SaaS model (Software as a Service). The benefit to this is typically a lower cost of entry, but greater cost over the lifetime of use. Though many Work Instruction Software platforms offer similar features, the functionality can be unique due to the production enviornment. It is important you select a vendor that understands your unique needs and can help ensure the technology is configured to match.
Security is also an important concern and should not be overlooked. While vetting your options, confirm that they deploy methods to protect your intellectual property as well as utilize redundant backups to prevent catastrophe. Finding a balance of security with ease of use will be paramount in gaining operator buy-in, as it is fairly common production operators do not have strong computer skills.
What are the Recommended Steps to Transition to Digital?
All change projects should start with a roadmap so the end goal is as concise as possible. World Class manufacturers rely on Production/Design Failure Mode Effects and Analysis (PFMEA or DFMEA) tools to predict and correct failures. We have created the inverse of that tool, and made the Project Success Mode Effect and Analysis (PSMEA). The PSMEA helps manufacturers identify what priority actions are needed to yield the greatest benefit to the organization. This toolkit is free, and we recommend downloading it below. Knowing what actions must be accomplished better equips you and your staff for future sales calls and product demonstrations.
Get the FREE Toolkit
How to Succeed with the Least Amount of Effort?
We at Scout Systems have created the Accelerator Program, a 90-day value-focused implementation of our platform. This program has such a high success rate that we back it with a full refund if at any point you feel our offering does not align with your needs. The goal of the program is to quickly transition factories to digital with the smallest financial and labor burden possible.
The best part of the Accelerator Program is that we make the decision easy on manufacturers. If you are deciding between Scout Systems and another platform, try us first and if it doesn't work out you have lost nothing. Chances are you will love our offering and we will do business for a long, long time.
By Eliminating Paper Usage in Factories
Safety is a top priority in any manufacturing environment, and reducing the risk of errors and accidents is critical to ensuring the well-being of workers and protecting the business from liability. One way to improve safety and reduce the risk of errors and accidents in factories is by eliminating paper usage. Let's review how transitioning to a digital factory can help reduce the risk of errors and accidents in a factory setting.
One of the most significant benefits of using digital work instructions in factories is that it can help standardize processes and reduce the risk of human error. Handwritten forms can be difficult to read and interpret, and mistakes can easily be made when transcribing information from one document to another. Digital documents, on the other hand, can be standardized and verified automatically, reducing the risk of errors and improving overall accuracy.
Furthermore, digital work instructions can be easily integrated with industrial IoT systems and technologies, such as manufacturing software and automation tools. This can help create a more efficient and streamlined workflow, reducing the risk of errors that can arise from manual processes and improving overall safety.
In addition to reducing the risk of errors, going paperless can also help factories avoid accidents and injuries caused by misplaced or lost documents. In a factory setting, paper documents can easily become lost or damaged, leading to costly delays and mistakes. For digital factories, backups and redundancies can be put in place to ensure that important information is never lost or compromised. This can help reduce the risk of accidents and injuries that can arise from missing or incomplete information.
Moreover, going paperless can help improve communication and collaboration among employees, which is essential to maintaining a safe and productive work environment. Digital documents can be accessed and shared from anywhere, making it easier for employees to work together and share information. This can help improve teamwork and cooperation, leading to better safety outcomes overall.
How to Embrace Digital
Of course, making the transition to a paperless system can be challenging. Employees must be trained on new systems and processes, and cybersecurity measures must be put in place to protect sensitive information. However, with the right tools, processes, and training, going paperless can be a relatively simple and straightforward process.
Scout Systems has the Accelerator Program - a 90 day blitz where we focus on the challenges of our customers and work closely with them to succeed, or give them their money back.
Eliminating paper usage in factories can help reduce the risk of errors and accidents, and improve safety overall. By standardizing processes, reducing the risk of human error, improving communication and collaboration, and avoiding the costs and delays associated with lost or damaged documents, factories can create a safer work environment and protect the well-being of workers. The Accelerator Program makes this transition an obvious decision.
As businesses seek to increase efficiency and reduce expenses, many are turning to paperless solutions. In factories, eliminating paper usage can bring significant cost savings that can positively impact the bottom line.
One of the most obvious ways that going paperless can save money is by reducing the costs associated with paper usage. Purchasing, storing, and disposing of paper products can add up quickly, especially for large-scale manufacturing operations. By switching to digital documents, factories can avoid these costs altogether and redirect resources towards other areas of the business.
Another way that eliminating paper usage can save money is by increasing efficiency and productivity. Digital work instructions can be understood more easily than paper documents, which can help reduce the time it takes new employees to learn a process. This can help streamline operations and improve overall productivity, allowing factories to produce more goods in less time.
Furthermore, going paperless can help businesses avoid the costs associated with lost or damaged paper documents. In a factory setting, paper documents can easily become lost or damaged, leading to costly delays and mistakes. With digital documents, however, backups and redundancies can be put in place to ensure that important information is never lost or compromised.
In addition to these direct cost savings, going paperless can also help businesses avoid fines and penalties for non-compliance with environmental regulations. Many countries and local jurisdictions have laws in place that require businesses to reduce their environmental impact by minimizing paper usage. Failing to comply with these regulations can result in significant fines and penalties, which can be avoided by going paperless.
Where and How do you Begin?
Of course, making the transition to a paperless system can be challenging. Employees must be trained on new systems and processes, and cybersecurity measures must be put in place to protect sensitive information. This is why we created the Accelerator Program - a 90 day initiative where we guide manufacturers in their transition to a digital factory. Going paperless can be a relatively simple and straightforward process with the right company.
While the transition to a paperless system may require some initial investment, the long-term cost savings make it a wise choice for any business looking to reduce expenses and improve efficiency. If you select Scout Systems, we honor a money back guarantee if at any point during the Accelerator Program you feel that it isn't the best fit for your organization.
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!