PERFORMANCE
Communication on the production line, still a problem?
22/03/2023
Temps de lecture : 5 min
Effective and relevant communication throughout the entire production chain is a considerable asset for an industrial group.
In a deskless environment, often extended, which includes a number of operational urgencies, communication enables the coordination and synchronization of the various steps of the production process by aligning production goals with supply chain objectives.
Circulating and providing access to key information during information routines (daily meetings, capacity planning meetings, S&OP meetings), and also outside of these, also allows field actors not only to identify but also to resolve a good number of issues.
Whether it's performance issues, capacity load, quality, supply, or safety, this allows for swift measures to be taken to resolve them.
You will have understood, a smooth communication of key information creates a virtuous circle within an industrial site, breaks down silos between the field and management, and will have a positive impact on indicators (lead time, service rate...).
Yet, effectively relaying the right information according to its criticality to different levels of hierarchy at the right time proves to be quite complicated.
What are the key pieces of information that must absolutely circulate to break down the barriers between different departments, and what means are available today to communicate them in real-time to the right people?
Key information
Here is a non-exhaustive list of information that the various actors in a production chain should be able to easily access in order to strive for optimal flow management as well as for a process of continuous improvement.
The information concerning production and its rhythm
The production objectives: Depending on multiple factors, objectives may need to evolve; each actor must be able to access them to be informed.
Production: The total number of units produced during a given period. A benchmark data, the baseline.
The evolution of load capacity: Having a view of this evolution allows, among other things, workshop managers to ensure monitoring and to motivate operators.
Production priorities: Operators must have a very clear view of the queues and priorities.
Information concerning primarily the supervisors and production managers
The machine availability rate: The percentage of time during which machines are available for production compared to the total available time. The machine availability rate measures the effectiveness of production equipment.
Raw material stocks: To evaluate response capacities to demand.
Unexpected events/incidents: Being able to quickly report a machine breakdown or an absence at a workload station allows for assessing the impact on production and quickly adjusting the plan accordingly, especially if these unforeseen events affect bottleneck positions.
Information concerning primarily logistics and supply chain managers
The most delayed parts: To prioritize the pieces to be processed at each station.
Raw material supply: To manage restocking needs.
The levels of finished product stocks: A key element to communicate to streamline production flows. Operators must ensure that finished products are available in sufficient quantity and in a timely manner.
Information concerning customer satisfaction
The service rate: This rate corresponds to the percentage of customer orders fulfilled within the stipulated time.
The lead time: This indicator facilitates the calculation of production times that impact logistics and commercial management.
The information concerning quality standards and other related information
The defect rate: The percentage of defective or non-compliant products compared to the total number of units produced. The defect rate measures the quality of production.
Customer feedback: Reporting negative feedback from dissatisfied customers about a particular product will impact the improvement of the product's quality to meet customer requirements.
Information related to the company
Press articles, awards, trade shows, new clients, results, seminars, events, etc.: This information is also important as it fosters the sense of belonging and commitment of employees and should therefore not be neglected.
For most industrial groups, obtaining, managing, and disseminating this information is done through a MES or ERP as well as through several Excel files. But despite the advantages these tools have, it must be noted that they have limitations.
The limits of ERP, MES, and Excel files
The ERP primarily allows for the centralization of data and processes within a company into a single system. It connects various departments and functions of the company, ensuring that information is shared and processes are optimized.
However, despite the advantages offered by the ERP, several limitations of this tool are still noted, such as:
Its complexity: Often very complex, it requires considerable training and expertise to be used effectively. This can lead to additional costs and difficulties for companies.
Its lack of accessibility: Not all actors in the company, especially field actors, can easily and daily access it.
Its lack of adaptability: ERPs are often designed to meet standardized needs and may not be suited to the specific needs of a company. This can lead to inefficient processes and additional costs for customizing the system.
Its maintenance and update difficulties: Regular maintenance and updates are necessary to remain effective and compliant with current standards, which can incur additional costs and service interruptions.
The MES (Manufacturing Execution System) connects and monitors production systems and complex data flows at the workshop level. Their objective is to ensure the effective execution of production operations and to improve performance. But they also have limits, often similar to those of ERPs, and present the following limitations:
Functional limitations: They also have functional limits. For instance, they may not be able to handle very complex production processes or adapt quickly to changes in production.
Reliability: MES systems may be subject to technical failures or human errors. The data produced by the systems must be reliable and accurate to be useful.
Regarding Excel files, limitations include the complexity due to the file size, as well as the inability to update them automatically, and the margin of error that manual processing causes. For more details, you can consult this article.
So what solutions currently exist on the market to address the limitations of ERPs and Excel files?
The new solutions promoting communication
Fortunately, for several years now, there have been several solutions on the market to take over Excel files and offer what a traditional ERP does not.
Often available as SaaS, these solutions will plug into the ERP to optimize the transmission and real-time updating of information on industrial sites (in addition to the other features they provide).
Oplit, for example, is a SaaS solution that allows for clear production priorities to be displayed directly on the shop floor via screens, tablets, etc. This tool provides visibility on the pulse of a production site (volume vs. goal, most delayed orders, risk of shortages, level of work-in-progress) and creates a common language between production teams and supply chain teams.
All stakeholders in the production chain, from management to the shop floor, can thus track multiple indicators through a complete and intuitive dashboard, communicate a production plan to the floor, and monitor its smooth operation in real-time.
Operators can visualize the queues and associated priorities at any time at a workstation, communicate any issues encountered, and anticipate upcoming actions.
Workshop leaders can track progress against the production plan goals, and sales administrators will be able to provide each customer with a reliable delivery date based on the estimated completion date of the production orders calculated by the solution.
Fabriq, also available as SaaS, is a workshop management solution that allows for capturing, keeping, and sharing information escalated during daily rituals across different levels of a company.
Finally, another solution like Juno will digitize an operational system, at scale, to capture field data and enable continuous system adaptation through analysis.
These solutions do not replace an ERP, but they provide functionalities that are only accessible through digital means and are essential for guiding a company smoothly towards an industry 4.0.
Conclusion
If in the past communication relied on rigorous processes that did not include or minimally included digital, it could hardly be very effective in facing variabilities.
Today, there are several solutions that will allow anticipating and managing them more quickly by providing autonomy to each stakeholder in the production chain through real-time transmission of the most relevant information to each of them.
