Misplaced inventory… this happens all the time, but it CAN be avoided.

As part of an employee’s initial training, they should be taught the importance of proper inventory handling. This training should occur even if inventory handling is not their job! Employees need to know how the actions (or lack thereof) of one individual affects the rest of the company and the system used to run your business. Proper inventory management is the responsibility of ALL employees. 

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If a particular machine in your shop breaks down a lot, and you are seeing lots of scrap on every job, maybe it is time to look at what is going on. Is there truly a problem with the machine? If so, get it fixed, or move production to another line. Maybe it is a problem with how the machine operator has been trained, or maybe it is due to poor quality materials that are being used as components on a given job. Until you dig in to find the root cause, you can’t fix the problem.  

Optimize Your Manufacturing Today!

When is the last time you took a hard look at your production lines?

• How are we moving product through our facility?
• Do we have work instructions / drawings available where needed?
• Do we have frequently used inventory available at the line?
• Where are the bottlenecks?
• Are processes automated, where possible?

Taking a hard look at your processes and procedures may reveal some interesting results. Don’t assume that everyone is doing things the same way. Some may be superstars, and others may need some mentoring. Some processes may be outdated and costing you time and money, while others are extremely efficient. One area of the business may benefit from how others operate. Take the time to review and analyze your findings. Your company may benefit greatly as a result.

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1. Collect the requirements. Learn from everyone with the intent of developing a phased approach to implementing on your shop floor with OEE being Phase 1. 
2. Create your list. Capture all of required functions, taking into account what the “output” of the system will be. What does the plant manager need to see in real-time? What KPI’s does each line need displayed in real-time? What reports are required?
3. Insist Upon Real-time. In the moment data for the right OEE is the right approach. If it’s possible, collect the data automatically. Remember that real-time feedback to line operators results in an automatic increase in OEE.
4. Evaluate your lines. Focus where production counts can be monitored automatically. If the data is in your PLC’s, can you get it out? OPC communication is the right way to go here. If not, the approach is to install a new dedicated PLC with sensors installed on each line.

Here are 5 ways you can motivate your employees to give their best every day:

1. Train Your Employees

2. Give Your Employees the Right Tools

3. Automate Processes

4. Give Your Employees Real-Time Feedback

5. Provide Incentives to Do More

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Previously, Material Requirements Planning (MRP) preferred practices meant that the component’s due date was the same as the parent’s shop order release date. Because MRP trends have changed, the preference for this due date is the day before the release date of the parent. Although Infor LX already has this functionality in Shop Order Maintenance programs (SFC500), users could not change how due dates were determined for lower level shop orders in Multi-Level Shop Order Release, SFC530D.

This enhancement provides an additional parameter for Multi-Level Shop Order Release. This parameter allows the user to change how the due date of the child components is determined. The user is now able change how the due date is determined for multi-level shop orders. If the Due Date of Children parameter is set to 1=Yes, the due date of the child components is the same as the release date of the parent. If the parameter is set to 0=No, the due date is the day before the release date of the parent.

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If you’ve been successful doing something in the past, you want to keep doing it that way. Are your procedures documented? Do you have workflows defined? Would creating video tutorials be helpful, especially for new employees? Giving employees the tools to be successful helps to ensure the success of the business as a whole.

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1. Eliminate paper shop packet and distribution of the paperwork to the shop floor.     
2. Eliminate manual (paper-based) recording activities and the need to key in the transactions.
3. Easy electronic scheduling by sequence and changing job priorities.
4. Evaluate differences using actual times compared to standards.
5. Improve data accuracy and eliminate the need to chase and fix errors.
6. Practice Real-Time data reporting to monitor efficiencies and identify problems as they occur.

Optimize Your Manufacturing Today!