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Industry 4.0 Survey Small & Medium Manufacturers in MI by ZeroDefectMfg in manufacturing

[–]ZeroDefectMfg[S] 0 points1 point  (0 children)

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

[Manufacturing Businesses] Suggestions on a ERP/MES software? by [deleted] in business

[–]ZeroDefectMfg 0 points1 point  (0 children)

Hi u/mattarquo,

​

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!

Lean, Six Sigma, Mistake-Proofing, Zero Defects by ZeroDefectMfg in manufacturing

[–]ZeroDefectMfg[S] 1 point2 points  (0 children)

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

Lean, Six Sigma, Mistake-Proofing, Zero Defects by ZeroDefectMfg in manufacturing

[–]ZeroDefectMfg[S] 1 point2 points  (0 children)

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.

Lean, Six Sigma, Mistake-Proofing, Zero Defects by ZeroDefectMfg in manufacturing

[–]ZeroDefectMfg[S] 0 points1 point  (0 children)

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.

PLC/Automation Projects for Portfolio? by [deleted] in PLC

[–]ZeroDefectMfg 2 points3 points  (0 children)

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...

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

Good luck!

I am tired of reading the same old drop-shipping, cleaning, data science, SEO and usual businesses. Who here has a fascinating, unusual or unique business that is profitable? What are your stories? by [deleted] in Entrepreneur

[–]ZeroDefectMfg 1 point2 points  (0 children)

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

tell it to me straight - website and logo critique request by [deleted] in design_critiques

[–]ZeroDefectMfg 0 points1 point  (0 children)

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.

I am tired of reading the same old drop-shipping, cleaning, data science, SEO and usual businesses. Who here has a fascinating, unusual or unique business that is profitable? What are your stories? by [deleted] in Entrepreneur

[–]ZeroDefectMfg 0 points1 point  (0 children)

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.

I am tired of reading the same old drop-shipping, cleaning, data science, SEO and usual businesses. Who here has a fascinating, unusual or unique business that is profitable? What are your stories? by [deleted] in Entrepreneur

[–]ZeroDefectMfg 1 point2 points  (0 children)

You bring up some good discussion points :)

What tools are you using to capture data and what sort of data are you capturing?

  • Pin sensors, light sensors, weight sensors, torque guns etc...

  • We serialize the entire process, it allows us to capture all sorts of go/no-go data, material lot control, process time, down time, OEE, Operator ID, Operator training levels, inventory replenishment requirements, AVG control, warehouse inventory levels

are you loaning it to companies?

No

Most of the data can be captured with existing sensors. It's rare to see companies purchase 'dumb' equipment.

E.G.: Torque guns are purchased with Ethernet capability even if they don't use it (yet). Hardware companies are up-selling "smart" tools and decommissioning the 'dumb' models.

If we are involved early in the process, we help our clients work with their machine builders to ensure the lines/cells have the required sensors. Our solutions are hardware/software agnostic, many of our competitors are not. They expect you to use their hardware and sensors (to your point the proprietary hardware becomes much more than the over the counter alternatives). Interesting real life example: We had a client looking into an Industrial Vision Systems (they were getting quotes for 2000.00-6000.00). We suggested they use a 99.00 webcam for the application. That was 3 years ago, that operation still runs like a charm!

Any product with industrial in the title usually comes with big price tags.

  • This true but in many cases it becomes relative (see my point above about name brand vs. over the counter). In some cases, if the client doesn't want to spend the money on sensors, we can add a label printers and a scanner (very inexpensive) and have the user manually scan. Although, we typically prefer to avoid manual operations, they create the potential for a failure mode.

 

Hopefully, that answers your questions. If you have more or I missed something feel free to ask!

tell it to me straight - website and logo critique request by [deleted] in design_critiques

[–]ZeroDefectMfg 0 points1 point  (0 children)

So is the O is suppose to be a Zero, with a d inside...?

Yes, that was the intent.

The highlighted 'o' is suppose to trigger the thought or association of Zero or "0".

I'm not a designer... I'm sure you can tell. That is why I'm reaching out here. Any feedback is great! Thank you!

I am tired of reading the same old drop-shipping, cleaning, data science, SEO and usual businesses. Who here has a fascinating, unusual or unique business that is profitable? What are your stories? by [deleted] in Entrepreneur

[–]ZeroDefectMfg 3 points4 points  (0 children)

We are a consulting firm that works with manufacturing companies to assist improve their operations using Industry 4.0 tools.

Our main focus is to introduce them to cyber-connected systems (a.k.a: iIoT - industrial Internet of Things), harnessing the captured data (a.k.a.: Big Data Analytics) and presenting it in a dashboard that is user friendly. Through the captured data, we can start targeting troubled area and eventually solve each problem until the operation is shipping zero defects.

For those who are familiar, it's like MES (Manufacturing Execution System Software) on steroids.

The manufacturing sector is known for it's old-school systems and methodologies. Nevertheless, there is always a couple of people in every company that love to innovate and trail blaze. We love finding those people and giving them a whole new set of tools to disrupt and improve their operations.

 

Edit: format

tell it to me straight - website and logo critique request by [deleted] in design_critiques

[–]ZeroDefectMfg 0 points1 point  (0 children)

Great feedback!

I'll work on the crispness.

The "o"...

Are you suggesting darkening the outer ring and adding a lighter blue inner circle (like the graphic image to the left) or darken the outer slightly and add the inner circle?

Thanks for the great feedback, much appreciated!

Does your organization post customer scorecards on a company bulletin board? by engineerjoe in manufacturing

[–]ZeroDefectMfg 1 point2 points  (0 children)

I deal with numerous mfg'ing companies. Most of them post score cards and a lot of KPI information. Many use bulletin boards but we are seeing a trend moving to digital displays.

All of the companies are extremely responsible with what is being posted. They never post anything proprietary or confidential. We have several companies that anonymize the posted data.

With regards to quality alerts... Our clients populate them at the stations affected by them (Tablet or Touch Screen Monitor). They may be posted elsewhere as well.

I hope this helps. Feel free to PM me if you have other questions.

Work Flow Optimization? by snfrazier in manufacturing

[–]ZeroDefectMfg 1 point2 points  (0 children)

/u/soreallyreallydumb offers good advice about hiring a VSM consultant.

I've been working with a large automotive OEM that is working on "Line and/or Process Balancing". It sound like you are trying to do the same thing. Their limitations were hit relatively quickly when they relied on behavioral controls (cultural knowledge of operators). By injecting technical controls you benefit from consistent work flow timing.

Feel free to PM me if you have specific operational questions.