As manufacturers struggle to reduce costs and improve production, more and more companies are turning to paperless manufacturing to improve quality.
As production grows increasingly more complex the Cost of Quality (COQ) is also increasing, with some companies reporting costs as high as 10% of revenue. The indirect and soft COQ may be even higher as you consider the non-value added time necessary to evaluate and address quality escapes.
When manufacturers consider initiatives to lower costs, quality is an emphasis. Modern MES and paperless manufacturing systems are delivering tremendous value to companies focused on improving quality.
MES and Quality Improvement
According to a white paper by Renaissance Services, the foundation of all quality escapes is the inability of the manufacturer to manage the details of production. The primary focus of paperless manufacturing and an MES is managing details through automation or providing the correct information at the right time and place in the production. Consider how paperless manufacturing addresses common sources of production errors:
- Planning errors.
This could be the wrong plans or the wrong technical specifications. Many of these are paper-based errors, and occur when the wrong plans are used, or critical information is missing from the work packet. An MES will ensure the proper planning and revision control, and make accessible all the information the shop floor needs at any time.
- Errors in approvals.
The approval process relies on communication and collaboration. Without a single source of manufacturing truth or a structure for communication and collaboration in the production process, errors occur during approval. Shortcuts are taken during approval, as the effort to coordinate the process increases. Improved quality relies on a disciplined approval process.
- Missing documentation from the Technical Data Package (TDP).
Many times with paper-based planning, documentation is left out because it isn’t considered necessary. This is especially true of the TDP. Critical documentation from the first article inspections is ignored or buried to reduce complexity or to speed up production and get a product to market – leading to errors.
- Ambiguity in the technical requirements.
Without automated quality checks during the production process, any ambiguity in specifications can lead to a critical quality error. For example, when a shop floor uses a paper spreadsheet to record production data, there’s no real time feedback loop on quality checks, and errors will occur. Quality assurance will find the error too late for corrective action.
- Requirements that are overlooked in production.
This comes down to inadequate documentation and processes during production. Requirements are inadequately communicated to the shop floor, or aren’t accounted for in the planning. Without real time quality checks or a method of managing production, critical requirements are ignored until problems occur.
- Changes in standard processes, especially special processes, in the production cycle.
Process enforcement in an MES or paperless manufacturing system ensures the shortcuts that often creep into manufacturing process are eliminated by ensuring documentation is reviewed and work signed off before planning is released. Without process enforcement, the shop floor will rely on processes they know, not the correct processes.
- Quality escapes that slip through inadequate first article inspections.
Often in paper-based or unstructured first article inspections, critical details can be lost, or there is an assumption on how work will be completed. This is especially true as the number of first article inspections increase at a site. Without adequate time, corners will be cut. With the automated records and audit reports created in an MES, critical details aren’t lost and are automatically recorded for future use, and the shop floor has more time to properly conduct a first article inspection.
Smart Manufacturing and the Future of Production
As complexity has increased in production, and the tolerance for errors has decreased, manufacturers can no longer adequately manage the information and detail necessary using error-prone paper planning and inefficient processes. Manufacturers need a comprehensive system to manage production.
Manufacturing needs aren’t slowing down. The complexity and technical requirements of manufacturing are increasing. Consider Smart Manufacturing – the integrated technology and systems essential for advanced Smart Manufacturing require an MES to manage production. Excel spreadsheets and Word documents simply can’t manage complex manufacturing processes.
Want to learn more, or see how a shop floor software system can improve your shop floor? Contact CIMx today for a free shop floor analysis to learn more.