You're struggling to meet manufacturing deadlines. What tools and technologies can help you stay on track?

Lot of manufacturing plants are deploying ERP Sytem without standardise their processes ,one of usual gap is not having standard part numbers which resulted in inefficiencies in the output and little utilization of ERP and not resolving most of problems

According To My Understanding And Experience To Overcome The Challenges Of Manufacturing; Any Company Big Or Small Must Have This One Document Which Will Later Also Become A Powerful And Irreplaceable Tool Is BoM (Bills Of Material). Having An Accurate And Updated BoM Will Allow Any Person Or Company To Be Fully Aware Of What Exactly Is Required To Manufacture A Particular Item. And Using The Data From BoM, A Tool Can Easily Be Created In Any Spreadsheet To Monitor The Progress.

There can not be a single solution. The tools can vary with respect to type of product. However, having spent 30 years in industrial beverages mfg, my opinion is S&OP (sales and operational planning) cycle is best tool. As an example, Commercial to project brand wise, SKU wise requirement, firm for a month and tentative for 5 months, every month! Operations/materials to plan for and procure, right materials at right time. Operations/HR to plan and make available manpower. Operations to make production schedules keeping best resources utilization with zero wastages. Quality to ensure minimum customer complaints. Finances to ensure minimum 'cost of finance' and HR to ensure maximum productivity by controlling FTE (full time equivalents).

Wrong. ERP does not manage all aspects of manufacturing. It controls costs, material costs, profits, inventory and incoming customer orders. ERP systems cannot help people anticipate problems before they occur, but only after the problems happened. A real solution that can proactively anticipate deadline problems is Production Planning and Scheduling solution, which is getting more and more separated from the cost-focused ERP system. Production Planning and Scheduling is a system independent from ERP because it predicts and oversees the growth of efficiency instead of the growth of financials, to realistically cut costs before production happens.

I agree a stable ERP system with focus on manufacturing activities encompassing all the processes starting from the part list, purchasing ,Inventory, BOM, manpower resources, shop floor control, WIP, warehousing, sales invoicing is the basic necessity to feel the pulse of day today operations.

1. Robotics: • Industrial Robots: Used for tasks like welding, painting, assembly, and material handling. Robots can operate 24/7 with high precision and consistency. • Collaborative Robots (Cobots): Designed to work alongside humans, these robots enhance productivity by performing repetitive or physically demanding tasks. 2. Computer Numerical Control (CNC) Machines: • CNC Milling and Turning • Additive Manufacturing (3D Printing) 3. Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs): • Material Transport 4. Programmable Logic Controllers (PLCs): • Control Systems: 5. Human-Machine Interfaces (HMIs):

Automation technology significantly enhances manufacturing efficiency by automating repetitive tasks and processes, reducing the reliance on manual labor. This technology includes robotics, automated machinery, and software systems that can handle production tasks with high precision and speed. By minimizing human error and streamlining workflows, automation ensures consistent product quality and helps maintain a steady production pace. It also allows for real-time monitoring and adjustments, enabling quick responses to any issues that may arise. As a result, automation technology helps manufacturers meet deadlines more reliably and efficiently, while also optimizing resource use and reducing costs.

We need to match the use of technologies with the size of production volume. At high volume of production, consistent demand, its great to automize, but for low production volume or seasonal, the use of automation tech could be as another cost.

1. Robotics: • Industrial Robots: Used for tasks like welding, painting, assembly, and material handling. Robots can operate 24/7 with high precision and consistency. • Collaborative Robots (Cobots): Designed to work alongside humans, these robots enhance productivity by performing repetitive or physically demanding tasks. 2. Computer Numerical Control (CNC) Machines: • CNC Milling and Turning • Additive Manufacturing (3D Printing) 3. Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs): • Material Transport 4. Programmable Logic Controllers (PLCs): • Control Systems: 5. Human-Machine Interfaces (HMIs):

In my experience with 3d printing a basic level of Automation is absolutely necessary in order to maximize your accomplishments. Due to long print times for larger models automation frees your focus to other crucial aspects of 3d printing business.

I am using AI in every area of the business. Use AI-powered software to analyse production data and identify patterns that might lead to delays. Implement predictive maintenance to prevent machine breakdowns. Integrate AI algorithms into your ERP system to forecast demand, ensuring adequate inventory and production planning. Use AI-powered MES systems to monitor production in real-time. Implement dashboards that provide live updates on production status and performance metrics. Use AI to analyse supply chain data, predict disruptions, and recommend alternative suppliers or routes. Integrate AI-driven quality inspection systems that use machine learning algorithms to detect defects in products during the manufacturing process.

In corporate sector, struggling to meet manufacturing deadlines, has an impact on revenue for an organization. For business solutions to the same, plant head in meeting with all the concerned, analyses the data & brainstorms in the meeting for proactiveness, to meet manufacturing deadlines.

Data analysis is the process of inspecting, cleaning, transforming, and modeling data with the goal of discovering useful information, drawing conclusions, and supporting decision-making. This process can be used in different contexts and areas, such as business, science, health, engineering and many others.

Importante manter uma rotina de análise destes dados, semanal ou quinzenal, vai depender da dinâmica, reuniões com os responsáveis e um plano de ação são boas práticas.

Acquiring and gathering right data is key so one can extract meaning out of it & turn it into (information), meaningful... Otherwise, analyzing data that is not pertinent will take time and gets you no closer to information state.

Wrong. Project Management is not a software suitable for manufacturing. Project Management System is used in non-manufacturing industries such as the service industry. A Project Management Software does not have manufacturing features like Throughput Time, Setup time, Changeover time management and well as material assigning, assembly/sub-assembly management, BOM management, machine attributes, and many more. In manufacturing industries, only a Production Planning and Control (PPC) solution is the system that provides features Gantt charts, resource allocation, and progress tracking, for a clear overview of future production timelines.

One of the most effective skills one can acquire. It can be used in almost any industry, too! Industries like Healthcare, food-processing, manufacturing, etc.

Project management is essential for meeting manufacturing deadlines by coordinating all aspects of production, from planning to execution. It helps set clear timelines, allocate resources effectively, and manage risks. Through careful monitoring and communication, project management ensures that all team members are aligned and that any issues are addressed promptly, keeping the project on track and within schedule.

Implementing Kaizens / Quick Wins Project management can be challenging especially when you hit a snag. It is recommended to identify quick wins (low hanging fruits), to boost morale and get some results. Once the team is motivated, it becomes easier to manage difficult solutions which can help meet milestones quicker with confidence.

The lean principle focuses on eliminating waste and optimizing processes to enhance efficiency in manufacturing. By streamlining workflows, reducing excess inventory, and improving quality control, lean practices ensure that resources are used effectively and production flows smoothly. This approach minimizes delays and helps manufacturers meet deadlines by prioritizing value-added activities and swiftly addressing any inefficiencies or bottlenecks that arise.

Uma mentalidade e práticas lean dentro de um processo produtivo corroboram para um nível de eficiência que seja competitivo as exigências de agilidade do mercado onde ferramentas como Kaisen, Six Sigma e e Kanban trazem melhorias continua, análise estatística do processo e controle de níveis de estoque aumentando a musculatura do processo para atendimentos aos prazos de entrega.

Quite useful if it is not viewed as a foreign philosophy and manufacturing only applicable. Lean philosophy simply looks for eliminating waste (Muda) to create value, and to serve customers. The tools and techniques are easy to master and use, but also easier to not master and not do, unfortunately!

Lean manufacturing provides flexibility, but can be expensive until you have all the elements in place. Lean will lead to meeting deadlines.

Flow. Ensure flow! Envision a Manufacturing set-up as an Electric Circuit and ensure continuous Flow of electricity through the same . Bulbs lit - flow is on . Some bulbs off - there is a circuit break / blockage / bottleneck ! That’s where you need to focus . Design AI to measure flow , bottlenecks etc .

In my view following are key benefits for efficient supply chain management 1. Efficiency in Production by demand forecast- ensures timely manufacturing, keeping your production lines running smoothly and avoid overproduction or stockouts. 2. Inventory Management: Efficiently manage inventory levels, ensuring you have the right materials at the right time without overstocking. Flow management is the key! 3. Supplier Coordination: reducing the risk of production delays. 4. Cost Savings: significant cost savings by reducing waste and improving resource utilization. 5. Customer Satisfaction: Ensuring timely delivery strengthens your reputation in the market

With my current experience, considering that the human resources and required equipments are available, supply chain management and a software tool for managing all required resources needed for the final product, will be enough to meet deadlines.

Heijunka！Heijunka！Heijunka！ Mura, Muri and Muda forms a dead triangle. Heijunka plus continuous improvement will be helpful

Ich empfehle die Every-part-every Intervall KPI zu verwenden. Darüber wird aus dem Wertschöpfungsprozess heraus daran gearbeitet eine höhere Flexibilität in der Produktion zugeleiteten, durch Rüstworkshops und optimale Rüstsequenzen, sowie eine Reduktion der Produktvarianten ermöglichen es die Fertigungsloßgrößen zu reduzieren. Das System kann durch die verbesserte Flexibilität wesentlich schneller auf Bedarfsschwankungen reagieren. Im Ergebnis reduzieren sich Materialbestände welches mit einer verbesserten Liefertermintreue einhergeht.