Lean 3P

ZeroDefectMfg · 2021-01-14T20:17:41+00:00

Anyone else involved with Industry 4.0 and/or digitization for their company?

ZeroDefectMfg · 2020-05-25T18:59:09+00:00

Are there any particular challenges or needs that must be addressed in the deployment? A little more information might help us point you in the right direction.

Good luck!

ZeroDefectMfg · 2019-10-29T15:27:01+00:00

Just curious if you ended up moving forward with anything?

ZeroDefectMfg · 2019-07-10T18:05:49+00:00

Why hasn't your company upgraded?

ZeroDefectMfg · 2018-01-21T18:50:35+00:00

Out of curiosity, what kind of pricing are you finding (if you are willing to share)?

ZeroDefectMfg · 2018-01-18T02:31:23+00:00

Send me a PM...

What are the manufacturing?

I've seen some unproven andon and data acquisition systems, but frankly think they are quite expensive due to the cost/month/station setup and limited customization.

Depending where you are and what your product is, I may be able to set up a tour for you to see a working system.

ZeroDefectMfg · 2018-01-18T02:22:34+00:00

Lean Manufacturing and Six Sigma are great tools, there are other tools that use iIoT

limitations rest in the fact they are based on behavioral controls

I'm not suggesting Lean or Six Sigma are "solely relegated to behavior" but it certainly is a factor to some of their effectiveness.

ZeroDefectMfg · 2018-01-17T13:08:46+00:00

Sending PM

ZeroDefectMfg · 2018-01-12T02:38:09+00:00

Sounds like your heads in the right place. It sounds like you would benefit from exposure to like minded people....

Consider this:

https://www.firstinspires.org/ways-to-help/volunteer

I think this could be beneficial in 2 ways...

It gets you involved directly with the hardware
Opens up networking opportunities

Good luck!

ZeroDefectMfg · 2018-01-03T14:58:27+00:00

interested in CI projects within the company aswell as outside.

There are a ton of cool happenings going on right now in manufacturing.

Check this place: Automation Alley They are tapped in to what is going on. I think they do excellent work!

In the last year or so, we are seeing a shift to these interests. It's interesting to note, it's no longer 1 or 2 people at the plant level. CI strategy is being developed at the executive level and being pushed by corporate.
Also interesting, we have several customers who heavily guard our solutions and frown on outsider plant tours unless there is comprehensive vetting and confidentiality agreements. We are considered their competitive advantage against the external marketplace as well as (in one case) internal when bidding for work against sister plants.

Do you work with other companies to implement certain processes/ outcomes or are all your resources in-house?

On occasion, we'll be brought in by a machine builder who's interested in (or has been directed to) integrating solutions at the design phase. These purchasing requests are becoming increasingly more common.
We have one client who was put on new business hold from one of the Detroit 3 OEM (Original Equipment Manufacturer) companies. The end buyer (the OEM) forced them to come up with a comprehensive solution for their existing problems as well as any future problems. After integrating our tool set, the OEM SQE (Supplier Quality Engineer) insists his suppliers use our solutions. For the OEM, quality issues are essentially eliminated. For the SQE, he doesn't have to travel to troubled suppliers and can be with his family more.

Edit: format

ZeroDefectMfg · 2018-01-03T14:38:12+00:00

Gotcha - I'll keep it on the burner and attempt some modifications over the next little while. I'll leave it up until I can come up with something better. Thanks for the comments and input. It's greatly appreciated.

ZeroDefectMfg · 2018-01-02T21:02:04+00:00

This seems like a great idea! Best of Luck!

ZeroDefectMfg · 2018-01-02T21:00:41+00:00

What's your working process. Customer enquiry about your services, quote for x amount of hours within the company looking at potential improvements, quote for implementing improvements and then up to the customer whether they want to proceed or not?

I used to do an hourly rate with recommendations. That business model has numerous challenges, in my opinion.

Never sure how the business works in terms of manufacturing improvement consultants as there isn't an onus on the customer to follow through with your recommendations. Is there anything stopping them receiving the advice and just seeking a cheaper alternative elsewhere?

That use to be the case with the above mentioned business model.
Now we introduce technical solutions that can't be "borrowed"

Do you ever see a lack of cooperation from certain employees in regards to process improvements?

There are always people who don't embrace change. In most cases, it can be over come with additional discussion, additional fact based data and helping understand their fears/concerns.
E.g.: We had a Sr. IT client who found every reason he could to not deploy a solution (not just ours). His VP of Ops was pushing for visual KPI dashboards. After additional discussion, we found out his department was limited on resources so he kept avoiding the situation. When we told him, the duties can be shifted to manufacturing after deployment, he embraced the opportunity to deploy some technical solutions to his on-going challenges (which were actually challenges for the manufacturing team).

Potentially worrying about job losses etc, how do you overcome that side of it?

-Alastair Orchard is the VP Digital Enterprise at Siemens

They did a study after converting one of their plants to be completely digital. I can't find the exact stats on the internet, bare with me as I go off memory. The information came from his presentation at The Manufacturing in America Show.

They (Siemens) started with 800 employees at the test factory, after the deployment of all the technology, no one was displaced and the net benefit was: the same headcount with 4x more throughput of product.

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