Shop Floor Errors Print E-mail
 
Manufacturing can be a complex process with high levels of change and stress. In most manufacturing companies, everyday errors cause waste, rework, loss of productivity and excessive cost. These errors are due to the complexity and dynamic nature of the shop floor and can make a company less competitive.  Errors also frustrate employees and cause lost time and opportunity.

 

There are five sources of errors:

 

· Machine wear out and variance

· Bad parts from suppliers

· Wrong or poorly made decisions

· Human error  
· Paper-driven processes

Machine issues will always occur and can be managed with diligent maintenance and repair procedures. Problems can be minimized, but not eliminated, since machines will always require maintenance and eventual replacement.

 

Bad parts from suppliers can be controlled through careful quality assurance, even though a few may travel into the production line.

 

Wrong or poorly made decisions are a special type of human error. Production decisions sometimes need to be made quickly without enough information. This can result in actions that must be reversed or modified, wasting both time and money. Instead, a real time view of the shop floor could improve quality and help remove the guess-work from production decision-making.

 

Human error can be traced to the misunderstanding of work instructions, using the wrong specification for a process, using obsolete information, choosing the wrong tool, setting up a machine wrong, or other production errors.  Having the right information always readily available on the shop floor can greatly reduce the human error factor. Staff can access clearly defined instructions when they need it and where they need it.

Paper itself is a cause of many errors. Obsolete or out-of-date work instructions cause production errors. Instructions that are missing a page or a critical drawing cause production errors. Paper tallies used to collect data from the shop floor can be misinterpreted when later entered into a digital system (such that quality measurements being taken incorrectly). Paper records lost or destroyed may not be able to be recovered. Eliminating paper instructions, can not only eliminate the costs of producing and distributing the paper itself, but guarantees you accurate and up-to-date, as well as recoverable and reliable work instructions at all times.

 

The last three sources of error; paper-caused, human error, and wrong decisions can be almost completely eliminated with a paperless manufacturing system.

CIMx has delivered this type of dramatic error reduction and quality improvement at a number of major companies including BAE Systems, Boeing, GE Aviation, Bell Helicopter, and others.

 

The average savings for a paperless system is $1,000,000 per year across the shop floor with a project ROI of less than one year.
 

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