Applied SmartFactory®’s Post

Chris Stergiou gives a great explanation of what companies tell the OEMs when looking for automation. When the end user is complaining about how bad the equipment is, I ask to see the specs given to the OEM. Most of the time, the equipment is built to those requirements and is being used differently. Maybe more questions should have been asked on both sides. Seen this in multiple industries across the country 😥

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Manufacturing Automation – the Need “Give us something simple to understand and maintain!” Was the REQUEST from an SME client recently as we reviewed their process for opportunities to decrease LABOR content through automation while being mindful of a previous FAILED attempt with an automation solution that was beyond the internal team’s abilities to understand and support … leading to ABANDONMENT and lost investment. Every manufacturing process has a CADENCE and a BALANCE, created over time and reflecting not only the EQUILIBRIUM reached with the available labor, materials and capital equipment used, but also reflecting the built in INEFFICIENCIES as functionality is seldom challenged by PERFORMANCE. These inefficiencies may be reflected of one or more of: Quality costs Order to Cash Cycle Time costs Capacity Limitations costs Material Waste costs Labor training costs Labor turnover costs Delivery delays costs Lost opportunities due to inability to deliver to customer demand costs Long setup times costs Inventory carrying Costs Work in Process (WIP) costs Like a series of gaps in windows that don’t quite close right, these ongoing costs may or may not be known and every process, no matter how well controlled, has these losses built into the process and offer opportunities to increase PRODUCTIVITY. The extent to which AUTOMATION has a part to play in capturing these benefits starts with: -      A fresh Value Stream Mapping of the process,   -      Speaking with and observing the Operators, -      Reviewing the quality and predictability of the Inputs, -      Thinking BIG but acting SMALL. It’s likely that the outcome will be a Right Sized, Simple and Cost effective solution that will not be REJECTED by the process. “Give us something simple to understand and maintain!” -- “Manufacturing Automation – How Much Does it Cost? The short answer: Nothing! It's free, since you're already paying for it without benefiting from it!” -- Are your automation solutions simple to understand and maintain? Your thoughts are appreciated and please share this post if you think your connections will find it of interest. 👉 Comment, follow or connect to collaborate on automation for enhanced productivity in your process. https://lnkd.in/ejBHzmjm #industry40 #automation #productivity #robots  

Empowering Manufacturers: From Siloes to Scalability Custom development in manufacturing has long been hailed as the beacon of innovation, tailored to meet specific needs and processes. However, in the pursuit of customization, we often encounter a critical challenge: siloes of data. These data siloes arise from disparate systems, each serving a unique purpose, but failing to seamlessly communicate with one another. The consequence? Fragmented insights, hindered collaboration, and inefficiencies that stifle growth. But fear not, there's a solution that brings harmony to this chaos: out-of-the-box solutions specifically geared towards manufacturers and Industry 4.0 initiatives. By embracing out-of-the-box solutions, manufacturers can unlock the scalability they need to thrive in today's dynamic market landscape. These solutions offer a unified platform, seamlessly integrating various functions from production to supply chain management. Here's how out-of-the-box solutions transform the manufacturing landscape: Unified Data Ecosystem: Say goodbye to data siloes! Out-of-the-box solutions consolidate data across departments, providing a comprehensive view of operations in real-time. Streamlined Processes: Simplify workflows and enhance efficiency by standardizing processes across the organization. From order management to inventory control, everything works in sync. Agility and Adaptability: In a rapidly evolving industry, adaptability is key. Out-of-the-box solutions offer flexibility to scale operations, integrate new technologies, and meet changing market demands. Cost-Efficiency: Custom development often comes with hefty price tags and ongoing maintenance costs. Out-of-the-box solutions offer a cost-effective alternative, with predictable pricing models and minimal maintenance requirements. Focus on Core Competencies: With out-of-the-box solutions handling the heavy lifting of IT infrastructure, manufacturers can redirect resources towards innovation and enhancing core competencies. In a world where agility and scalability reign supreme, out-of-the-box solutions emerge as the catalyst for manufacturing success. Let's break free from the shackles of data siloes and embrace a future of seamless integration and growth. Check out Conperio's out-of-the-box solutions here: https://lnkd.in/gyAgdB4 #Conperio #BridgingtheGap #Manufacturing #DigitalTransformation #OutoftheBoxSolutions #Scalability #Innovation

Manufacturing Automation – Take fresh look Review the process, one work-cell at a time! Many legacy processes have been around for a very long time and under the best circumstances have evolved and have been optimized to some UPPER LIMIT set by the inherent process architecture and sequence steps. Not much “meat left on that bone”. Informed by the underlying sequence takt times, MUST HAVE conditions and throughput possible, we can sometimes break the limitations by changing the sequence of operations, changing workflows or significantly speeding up some limiting step and thereby transforming and truly disrupting that mature process. An outcome of a common approach used in Lean Manufacturing, (eliminating Muda), this mindset redefines the process and instead of focusing on the metrics of the current state, it focuses on more qualitative attributes and seeks to ... “MOVE IN A POSITIVE DIRECTION” ... having blind faith that by doing so, the entire process will improve with quantification of those improvements TBD after the NEW PROCESS is deployed. Qualitative attributes of the POSITIVE DIRECTION, generally include: -         Significantly decreased number of product “touches”. -         Significantly decreased “residence time” at each and any step. -         Significantly decreased product workflow travel distances. -         Significantly decreased worker travel distances. For Hi-Mix, Low-Volume SME processes this can be particularly challenging as the universe of steps may not always be required for any/all of the products yet traveling through these steps or having to optimize the by-passing of these steps is the CHALLENGE in the quest to achieve LOT SIZE ONE efficiencies and the ultimate productivity metric of lowered ORDER to PAYMENT cycle time metric which best defines, PRODUCTIVITY. Compounding the challenge is the labor content at each process step and while the Hi-Mix often thwarts justification of automation …. Still there is room for PROPERLY SIZED, targeted, custom automation to move the new process in the POSITIVE DIRECTION. Review the process, one work-cell at a time! -- “So how might we start? Think BIG – Act SMALL Surveying the plant, it is often easy to “see” process automation opportunities in many manufacturing steps that have remained mostly manual or with minimum automation.” -- How do you move the process in a positive direction with automation? Your thoughts are appreciated and please share this post if you think your connections will find it of interest. Leave a comment or connect to discuss how to strategically implement automation for increased productivity. https://lnkd.in/e45BKyxW #industry40 #automation #productivity  

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Info-Tech Research Group captures key details about software performance in their Buyer Experience Guide to help manufacturers like you evaluate, compare, and ultimately select the best #MES for your business. See how our MES solutions rated in key areas now.

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Optimizing PPH Expectations for Mixed Depalletization Scenarios When dealing with packages of varying sizes and quantities, larger boxes and irregularly shaped bags will require more time to handle than uniform, smaller items. To account for this variability, adjustments to PPH expectations must be made. When handling heavier objects, metrics such as tons/hour, total number of pallets processed, or dock turn times should be considered. A narrow approach to system optimization, based on a limited number of metrics may not accurately reflect everyday activities. This a multifaceted issue, and to succeed in their automation journey, companies must consider the bigger picture. Download the whitepaper here to read more: https://loom.ly/_5vyTBs #technology #industrialengineering #automation #industry #automationengineer #vendormanagement #manufacturer #manufacturers #innovation #management #technology #robotsworkpeoplerule

INDUSTRY NEWS: An exploration of the distinct hurdles manufacturers encounter when pinpointing processes conducive to automation and strategies for synchronizing their automation endeavors with overarching business objectives. #Automation #Manufacturing #IndustryNews