Process transparency is the first step of factory management.
The factory has unexpected conditions to deal with every day. Even if you arrive at the scene, you can’t solve the problem. The problem can only be seen if the whole picture is presented.
1. It is hard to determine whether there is a shortage of material when we can’t monitor the status of each production process.
2. It is time consuming and easy to make mistakes where workers need to input the production information manually half an hour before the end of work.
3. Even though machine standing rate is 100% but we couldn’t identify the profit-making rate for a machine.
4. When there a complaint from customer, are we able to find out the problematic raw material or component batch number and process? Are these defective parts used in other semi-finished products of shipment?
5. What is the outsourced production schedule? Will the quality be delivered?
6. Problems can’t be figure out immediately due to production information can only be done during the noon and off-duty hours.
7. It is difficult to get extra time consuming when small batch orders and customize items bring changes in production line.
EMMT SYSTEMS CORPORATION
Visual management at your desk
In ERP based information platform, how can we cope with the change of order receiving pattern from the military market to the commercial market to monitor process, complete rate, material shortage and production line planning? Process transparency can be controlled by implementing Shop Floor Tracking (SFT) production tracking system in year 2012 while visual management can be carried out by using Kanban. In 2013, in order to improve efficiency, Radio Frequency Identification (RFID) is implemented and it has increased the reporting time of each process. In the process of transfer, sensor on RFID Reader sensor synchronize immediately to capture production status such as personnel information, inbound and outbound information.
There is a magic weapon in factory management
You no longer need to think of factory inspections as fitness exercises
Through scheduling planning, you can precisely control the balance between production and material control, reduce the occurrence of inventory and sluggish materials, and deliver on time to improve customer satisfaction.
Electronic Work Instructions (eSOP)
▶ eSOP can solve the following problems.
1. Difficult to maintain and manage
The paper SOP will have storage and searching problems, resulting in a waste of time. There may be missing pages or unclear display due to improper keeping, resulting in missed production actions and abnormal production.
2. Risk of taking the wrong paper SOP
Lead to production of defective products.
3. Time taking for searching in paper SOP
It might take more time to search in paper SOP due to numerous of content.
eSOP can be send to different screens according to the number of people and pages automatically.
Eg: There are four workers set to be handling the assembling process, system send four different SOP files to the tablet or screen automatically.
There are variety types of Kanban, such as reflect production status of the order, to check if there is any shortage of materials. Indicator in Kanban provide real-time status and it could be trace into details for monitoring and handling abnormal issues.
- Production Kanban by batch
- Production Kanban by Job Order
- Dispatching Kanban
- Expected processing Kanban
- Overdue Kanban
- Idle Kanban
eKB Electronic Signage Benefits
|Benefit||Before Implementation||After Implementation|
|Presenting production process||Time difference occur when check manually by personnel||Real time status reflects on Kanban|
|Effective communication between department||Time consuming and rework is needed when generate reports by using excel.||Create visual management and communication platform of various departments|
|Custom made Kanban and reports||Customize is needed when there is new requirement||Customize Kanban easily|
|Clearly stated of corporate goals||Changes only made when report being presented during meeting which is less efficiency||Goals achieving can be monitor from time to time which improve efficiency|
Production report output
System user friendly is the key of success to report the production output, which makes much easier for foreign workers and senior superior to use it. It can also combine RFID to complete the scanning (reporting) operation at the same time, which will increase the accuracy of the data and reduce the input time to achieve transparency in production progress and working hours.
User can flexibly set the reports format which contains job order release, work-in-progress tracking, outsourcing tracking, disassembling, defective products grades until closing of order.
- Web platform that enable subcontractor to access online according to the authority.
- Simple interface that includes inbound and outbound operations.
- The subcontractor able to plan their capacity based on pending job order with the expected start date.
Grain or dynamic management
The running rate indicates full capacity, but is it really impossible to improve?
How can we know whether capacity has been fully maximized after we spending so much on equipment? What is the reason of the capacity loss of equipment? Can we increase the capacity when the dynamic rate is full? Do we know how much capacity is wasted in waiting and changing production line? Data is the best proven of reasonable capacity instead of experience.
Integration of the machine
In the process of data collection and process control, we need to ensure correctness amount of materials before feeding, regular inspection during the manufacturing process, and analyze the reasons for defective goods. Are all these processes of manual control often negligent? In the future, you can improve management efficiency by using system which can control by changing status into online and real time.
Traceability of product
Traceability will be the basic condition for manufacturers to take orders.
The purpose of traceability of product are to reduce customer complaints and unnecessary cost. When customer complaints occur, we should able to find out the problematic parts from semi-finished product to finished product, which lot it comes from, the sources of materials and where do we sell. Traceability of product has become one of the competence due to requirement of customer has increase in order to ensure the product quality and increase customer satisfactions.
Industry Case Studies
From left: Ms Jasmine Kang (Project manager), Ms Lok Kah Mun (ERP Project Manager), Mr Kang (Director of Dee Noon), Ms Khor (Project manager) Dee Noon Corporation Sdn Bhd (Dee Noon) was established on May 2006. Managing director of Dee Noon, Mr Kang and his team...
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