We talk with a lot of manufacturers, especially high mix/low volume shops, which have challenges with their production schedules.
Typically, ERP systems don’t have great scheduling modules. Too often those production schedules are pipe dreams because they expect the world to be perfect…like an automotive manufacturer that has near-complete control over the supply chain, machine uptime, workforce, etc. You likely do not have that kind of control. The predictions are often too optimistic and end up being inaccurate more times than not.
There is hope, don’t lose faith!
In this article, we will go over two ways to get better, more accurate production schedules.
Accurate Cycle Times- having accurate cycle times and very good data on the job setup and changeover times for jobs helps immensely in improving estimates for jobs so you lose money less often on jobs. This data also helps more accurately predict the actual time it’ll take for the job to move from station to station through the shop. This helps you but will also give the customer more clarity, and will make for a smoother transaction if the estimate that you gave the customer actually ends up being accurate at the end of the deal. A happy customer will help build your reputation as a knowledgeable and trustworthy manufacturer which will encourage a lot of customers to continue doing business with you.
This is why using an Industrial Internet of Things system to pull machine data is so important for you. The more data you have the more you will learn and understand about the machines. Over some amount of time, you will start to really see what is happening which will make it much easier to predict an accurate time. Also, this way it will be a more confident prediction, and completely data-based. Making a data-driven decision makes the process a lot clearer and will give you some real in-depth substance for more accuracy in your decision making.
You can have better communication and valuable updates with the customer this way. Everyone involved in the project will be better educated. This makes the entire plant more efficient and leaves you with a happier customer with a project finished on time that was planned and executed the way they were told.
Actual vs. Planned- data should be available from your systems for how well the production schedule performed. This data should also be available in real-time, no waiting for someone to manually calculate and analyze actual vs. planned to provide a report. When this real-time data is available performing a post-action review on your production schedule your team can get a lot of valuable lessons for how to improve the production schedules. A prime example of how important real-time data is for multiple reasons. Use the data to avoid problems before they happen, but it also helps to continually educate people on the plant floor that have complete visibility into the machines. Everyone will develop a deep understanding of machines across the plant, which will assist them in making the right decisions to keep projects on schedule.
Do you have this kind of data available to you? I hope so. If not, look to your Industrial Internet of Things/Manufacturing Analytics product. These should be out-of-the-box capabilities. Additionally, the Industrial Internet of Things/Manufacturing Analytics solution should also integrate well with your ERP system and automatically share the data. We have a lot of experience and help with these kinds of situations all the time. If you have any questions or want to get in touch call or email anytime, we are more than happy to see if we can help. https://ectobox.com/sensrtrx/