Maintenance Support Solution Factsheet

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Overview

Of all the sources of waste in the manufacturing environment, unplanned stoppages represent one of the largest contributors. From unreliable equipment to overly complex processes, these events can derail the goals of the manufacturing organization and result in substantial costs in both money and reputation.

Fortunately, this type of waste is fairly easy to treat. Alongside a disciplined maintenance procedure, reliable and quantifiable data can help lead preventative maintenance activities in the right direction, treating the root cause of downtime and measuring the effectiveness of remedial activities.

Maintenance Support Quick Reference Guide

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Our Manufacturing IT Solutions offer off-the-shelf functionality designed to eliminate the typical challenges encountered in manufacturing operations. They are highly scalable and cost effective and can be seamlessly integrated into new or existing processes with great ease. Maintenance Support tools are designed to help you increase the efficiency of your facility through the reduction of unplanned downtimes and better preventative maintenance.

The Technology

Alarm Annunciation and Alerts
Increases maintenance teams reaction times with visual and mobile alerts
Reactive Maintenance Management
Generates and manages maintenance orders based on unplanned events
Preventative Maintenance Management
Prevent unplanned downtown with preventative maintenance triggers
Integration with Maintenance Systems
Seamlessly integrates with your systems or functions as a stand alone solution
Continuous Improvement Reports
Focuses continuous improvement efforts through fact driven event reports

Inventory Management Solution Factsheet

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Overview

One of the principal forms of waste in manufacturing results from excess inventory of both production materials and Work-In-Progress (WIP). This form of waste can cause a financial burden and an unnecessary use of the manufacturing space.

Non-Value Added time associated with the location and retrieval of production materials and WIP, also negatively impacts manufacturing performance.

Our Inventory Management tools can help reduce both forms of waste by automating the management of materials and WIP within the production facility.

Inventory Management Quick Reference Guide

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Our Manufacturing IT Solutions offer off-the-shelf functionality designed to eliminate the typical challenges encountered in manufacturing. They are highly scalable and cost effective and can be seamlessly integrated into new or existing processes with great ease. Inventory Management can reduce Non-Value Added time and financial burden by keeping track of inventory levels and locations during the production process.

The Technology

Asset Tracking
Automated location services for storage and retrieval
Material Stock Level Management
Automate stock re-order based on level and lead time
Material Containment
Manage risk by controlling obsolete or faulty stock
Inventory Optimization
Eliminate waste by controlling optimal material levels
BOM Stock Check
Prevent “false starts” by confirming material stock levels before manufacturing begins

Picking and Kitting Solution Factsheet

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Overview

Today’s manufactures are faced with many challenges when it comes to their logistics operations. Reducing costs, increased variability and quality issues are common obstacles to increasing profitability.

Effective logistics solutions can help with these common challenges, allowing production manufacturing to operate quicker, more cost effectively and with higher product quality.

Sequenced part kitting operations remove the burden of correct part selection from the pressured environment of the production line, making assembly operations faster with fewer errors.

Picking and Kitting Quick Reference Guide

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Our Manufacturing IT Solutions offer off-the-shelf functionality designed to eliminate the typical challenges encountered in manufacturing. They are highly scalable and cost effective and can be seamlessly integrated into new or existing processes with great ease. Picking and Kitting help with increasing efficiency and eliminating errors within logistics operations.

The Technology

Paperless Kitting Screens
Electronic delivery of picking and kitting instructions
Pick-to-Light
Providing a high-level of process security
Pick by Voice
Allows for high level of variability and eliminates user error
Sequence Cart and Reverse Sequence Picking
Optimal sequencing operations for line-side delivery
Picking Path Optimization Tools
Reduced operator travel paths increase efficiency and eliminate waste

Error Proofing Solution Factsheet

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Overview

Error Proofing (or Poka-Yoke) is a remedy for one of the ‘7 wastes of lean manufacturing,’ specifically defects. Quality errors that cause defects require rework or replacement and utilize additional resources and materials that ultimately lead to additional costs and potential loss in customers.

Early on in the development of lean manufacturing processes it was identified that defects, amongst all the types of waste, are the most challenging to control with process design alone. Instead, many tools and techniques have been developed over time to help eliminate this source of waste from the manufacturing process.

Error Proofing Quick Reference Guide

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Our Manufacturing IT Solutions offer off-the-shelf functionality designed to eliminate the typical challenges encountered in manufacturing. They are highly scalable and cost effective and can be seamlessly integrated into new or existing processes with great ease. Our Error Proofing tools can help reduce waste in the form of defects and increase productivity in the modern manufacturing facility.

The Technology

Work Instruction Screens
Providing process guidance through graphics and video
eChecklist Screens
Text based work instruction list with operator feedback
Material Checks
Confirm material compliance or record serial numbers
Pick-to-Light
Providing a high level of process security
Kitting
Electronic delivery of picking and kitting instructions

Work Instructions Solution Factsheet

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Overview

Wherever complex assembly processes are carried out manually, especially where product diversity is a factor,
there exists the possibility of mistakes being made.

For today’s manufacturer, every second counts and every mistake made can cost you your reputation and your money. For this reason, the need to provide precise guidance and ensure compliance, is higher than ever before.

To help mitigate mistakes, detailed instructions and cross checks can be implemented to take the guesswork out of the process and help prevent costly issues.

Work Instructions Quick Reference Guide

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Our Manufacturing IT Solutions offer off-the-shelf functionality designed to eliminate the typical challenges encountered in manufacturing operations. They are highly scalable and cost effective and can be seamlessly integrated into new or existing processes with great ease. Work Instructions and Quality Control Solutions can be extremely beneficial when looking for a way to help eliminate errors that arise due to complex and highly variable work activities.

The Technology

Work Instruction Screens
Providing process guidance through graphics and video
eChecklist Screens
Text based work instruction list with operator feedback
Material Checks
Confirm material compliance or record serial numbers
Zone Quality Check Function
Create quality gates with the zone checker feature

Yard Management Solution Factsheet

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Overview

Management of work-in-progress or finished product storage (typically referred to as Yard Management) is a critical link in the manufacturing chain.

Product within storage represents high value inventory which ultimately must be processed or shipped to realize its value potential. For that reason, an efficient use of storage is a must for maintaining profitability and reducing excess inventory.

Additionally, inefficient yard management can adversely affect delivery schedules, risking reputation and profit.

Yard Management Quick Reference Guide

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Yard Management is part of our new line of Manufacturing IT Solutions. Built on proven, world class technology, these solutions offer off-the-shelf functionality designed to target the typical challenges encountered in manufacturing. The technologies are highly scalable, cost effective and can be seamlessly integrated into new or existing processes with great ease.

Our Yard Management Solution allows you to take control of the storage and retrieval of work-in-progress and finished product within the manufacturing facility.

The Technology

Yard Configuration
Configure and display and exact replica of the storage yard
Transaction Control Center
Provides access to all scheduled product movement transactions
Mobile Application
Supports delivery and retrieval operations

Genealogy and Build History Solution Factsheet

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Overview

Increasingly complex products, materials and processes, high efficiency demands resulting in shorter cycle times and higher quality targets coupled with surging regulatory compliance requirements has led to a dramatic demand for transparency in the manufacturing process.

Over the last few years we have seen an increasing trend of product recalls resulting in damage to companies’ financial standing and reputation.

That’s where a well planned containment strategy combined with comprehensive Build History and Genealogy data can provide significant support

Genealogy and Build History Quick Reference Guide

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Our Manufacturing IT Solutions offer off-the-shelf functionality designed to eliminate the typical challenges encountered in manufacturing. They are highly scalable and cost effective and can be seamlessly integrated into new or existing processes with great ease. Our Genealogy and Build History tools can help minimize the risks inherent with todays complex products and provide comprehensive containment in the case of a product recall.

The Technology

Dynamic Build History
Electronically record all activities and materials
Containment Reports
Accurately identify product lists from material batches
Material and Batch Scans
Confirm material compliance or record serial numbers
Zone Quality Check Function
Confirm material compliance or record serial numbers

Plant Visualization and Alarm Monitoring Solution Factsheet

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Overview

With greater reliance on automation and increased complexity in manufacturing processes, the need to effectively visualize production operations has become extremely important.

The ability to not only view, but analyze the production process, provides measurable metrics that can help drive more effective performance and reduce costs.

Real-time dashboards keep key personnel in touch with the immediate situation as it occurs on the manufacturing floor, fostering an agile and timely response, keeping operations on track.

Plant Visualization and Alarm Monitoring Quick Reference Guide

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Our Manufacturing IT Solutions offer off-the-shelf functionality designed to eliminate the typical challenges encountered in manufacturing. They are highly scalable and cost effective and can be seamlessly integrated into new or existing processes with great ease. Plant Visualization and Alarm Monitoring gives you the ability to not only view but analyze the production process. This solution provides measurable metrics that can help drive more effective performance and reduce costs.

The Technology

Visualization Screens
Puts real-time information in the hands of those who need it
Production Reports
Drive production meetings with facts, figures and trends
Maintenance Reports
Keeps maintenance operations on task with statistical analysis
Process Specific, Real-Time Screens
Delivers process-specific KPIs on customized screens
Historical Data-Mining and Analysis Tools
Provides deep analysis of trends and effects of improvement efforts

Manufacturing IT Solutions Overview Solution Factsheet

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Overview

Today’s manufacturer faces a number of challenges. With increasingly complex processes and the need to stay competitive, goals such as increasing productivity and minimizing costs can seem daunting.

Manufacturing IT can play a significant role in realizing the challenges of the modern manufacturer. It can help optimize production through increased visibility and control of the manufacturing process. This overview breaks down the major building blocks of Manufacturing IT and identifies the tools that address these common challenges.

For a more detailed view of some of the specific solutions within Manufacturing IT, look for the links to our Manufacturing IT Solutions Factsheets.

Process Visualization

Effectively visualize production operations to drive performance and reduce waste

The effective operation of manufacturing facilities can be greatly enhanced by the provision of an accurate, real-time depiction of equipment and work-piece status. The increased availability of technology within a typical manufacturing facility provides the perfect environment to implement this increasingly important facet of the modern manufacturing world.

Specific Solutions: Plant Visualization and Alarm Monitoring

Tools

  • Equipment Status Displays
  • Work-Piece Status and Process Flow Displays
  • Calculation and Display of KPIs
  • Alarm Monitoring and Notification
  • ANDON Displays

Order Management

Coordinate and control the manufacturing operation to the required
work orders

The manufacturing facility is a complex environment with one end goal – to produce product according to the needs of the consumer. These Order Management functions are designed to coordinate the various operations within the facility to insure a timely and high-quality delivery of the desired products.

Order Management functions effectively establish the production goals and provide the manufacturing facility with the data and materials to produce according to the consumers needs.

Specific Solutions: Genealogy and Build History, Yard Management

Tools

  • Work-Piece Sequencing
  • Process Data Collection and Analysis
  • Rework Management
  • Work-Piece Genealogy and Build History
  • Yard Management and Product Delivery

Manufacturing IT Solutions Overview

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Today’s manufacturer faces a number of challenges. With increasingly complex processes and the need to stay competitive, goals such as increasing productivity and minimizing costs can seem daunting.

Manufacturing IT can play a significant role in realizing the challenges of the modern manufacturer. It can help optimize production through increased visibility and control of the manufacturing process. This overview breaks down the major building blocks of Manufacturing IT and identifies the tools that address these common challenges.

The Solutions

Picking and Kitting

Picking and Kitting help with increasing efficiency and eliminating errors within logistics operations. Technologies include: Paperless Kitting Screens, Pick to Light, Pick by Voice, Sequence Car & Reverse Sequence Picking, and Picking Path Optimization Tools.

Plant Visualization and Alarm Monitoring

Plant Visualization and Alarm Logging gives you the ability to not only view but analyze the production process. This solution provides measurable metrics that can help drive more effective performance and reduce costs. Technologies include: Visualization Screens, Production Reports, Maintenance Reports, Process Specific Real-Time Screens, and Historical Data-Mining and Analysis Tools.

Work Instructions

Work Instructions and Quality Control Solutions can be extremely beneficial when looking for a way to help eliminate errors that arise due to complex and highly variable work activities. Technologies include: Work Instruction Screens, eChecklist Screens, Material Checks, and Zone Quality Check Functions.

Inventory Management

Effective logistics operations can minimize waste in material inventory, reduce the risk of downtime through material starvation, reduce material footprint within production areas and even enhance quality and reduce cycle time by transferring material selection operations to within the logistics areas.

Genealogy and Build History

The manufacturing facility is a complex environment with one end goal – to produce product according to the needs of the consumer. These Order Management functions are designed to coordinate the various operations within the facility to insure a timely and high quality delivery of the desired products.

Maintenance Support

Of all the sources of waste in the manufacturing environment, unplanned stoppages represent one of the largest and one of the easiest to treat. Providing detailed real-time information can create a faster response and hence a faster remedy. Historical data analysis aids continuous improvement processes. Reactive and Planned Maintenance management creates discipline in remedial activities. Technologies Include: Alarm Annunciation and Alerts, Reactive Maintenance Management, Preventative Maintenance Management, Integration with Maintenance Systems, and Continuous Improvement Reports

Error Proofing

Product variability, manual operations, high complexity and limited time all mean that assembly operations are one of the key areas where production enhancements can be realized.

Yard Management

Our Yard Management solution allows you to take control of the storage and retrieval of work-in-progress and finished product within the manufacturing facility. Technologies include: Yard Configuration, Transaction Control Center, and Mobile Applications.