by Gary Mintchell | Sep 26, 2024 | Manufacturing IT, News, Organizations
My long-time colleague Julie Fraser is still at it. I remember the room where the Manufacturing Enterprise Solutions Association International (MESA) announced its first Metrics That Matter study. It was 2006.
The Manufacturing Enterprise Solutions Association International (MESA) is working with Tech-Clarity, Inc. on the next iteration of its long-standing Analytics that Matter research program. Formally launched during the MESA Smart Manufacturing NOW virtual event, this research will review manufacturers’ progress in performance metrics and analytics and explore the value manufacturers and producers can gain from using artificial intelligence (AI).
MESA and Tech-Clarity will conduct a survey to understand the goals, challenges, and successes companies have for their analytics and AI initiatives. They will share the findings in a research report, infographic, and webinar during the first half of 2025. The survey will be open for manufacturers’ responses later in 2024. To date, the program has three sponsors: Aegis Software, Epicor, and GE Vernova. The program is capped at six sponsors, so additional sponsors are welcome. For more information about sponsorship, please contact Julie Fraser at Tech-Clarity, [email protected].
Making Analytics and AI Matter is the continuation of an 18-year MESA initiative focused on uncovering the value of analytics through an online survey of manufacturers and producers worldwide across process, batch, and discrete industries. Tech-Clarity, MESA, and the sponsors will collaborate to develop the survey. The 2024-25 study continues work that began in 2006 under Julie Fraser’s guidance. This round extends it to reflect the growing role of not only metrics and analytics but AI and generative AI in manufacturers’ success.
Fraser will again lead the research program, supported by MESA’s Knowledge Committee and Analytics Working Group. Some questions will be based on previous MESA Analytics studies so the team can analyze trends and progress. In the last study, industrial analytics showed the quickest time to impact among various IT projects, and more respondents had live advanced analytics projects in 2022 than in previous surveys. New questions will focus on the impact of GenAI, what types of analytics work best where, and what helps AI to deliver its full value in production companies.
MESA’s International Knowledge Committee and Analytics Working Group Chair Chris Monchinski of InflexionPoint says, “We have seen the value of this analytics research over the years. It shows progress in manufacturers’ technology use and business understanding. Now, we will explore both traditional metrics and analytics and the uptake of the newest AI and GenAI technologies to deliver manufacturing insights. MESA’s Analytics Matter podcast has supported these topics for several years. Now, we will have new quantitative research to understand where the value lies.”
“Manufacturers have long known there is more they could do with their data. This research aims to demonstrate what they are doing to analyze their data to create actionable insights and high-value improvements from descriptive, diagnostic, predictive, and prescriptive analytics and current AI approaches. MESA Members and study sponsors will get invaluable learning from sharing experiences,” Tech-Clarity’s Vice President of Research for Operations and Manufacturing Julie Fraser remarked. “We are grateful for the sponsors who have already stepped up to ensure this industrywide research can continue in this time of rapid progress in AI and looking forward to welcoming a few more sponsors to the team.”
MESA conducts this study with a research partner every few years. In November 2024, look for a press release inviting manufacturers and producers to take the survey. Then, in 2025, we will announce the release of the findings report, infographic, and webinar. MESA members and sponsors will have special access and rights to these survey deliverables.
Tech-Clarity is an independent research firm dedicated to making the business value of technology clear. We analyze how companies improve innovation, product development, design, engineering, manufacturing, and service performance through the use of digital transformation, best practices, software technology, industrial automation, and IT services.
Manufacturing Enterprise Solutions Association (MESA) International has been helping the global manufacturing community use information technology to achieve business results through premier educational and research programs, best practice sharing, and networking since 1992. MESA is a 501(c)6 not-for-profit trade association. The Manufacturing Enterprise Solutions Association (MESA International) is a global community of industry thought leaders actively driving business improvement through the effective application of technology and best practices.
by Gary Mintchell | Sep 24, 2024 | Manufacturing IT, Operations Management, Software
MachineMetrics positions itself in the analytics space translating from operations to ERP. It has released a scheduling solution called Production Schedule Intelligence touting scheduling accuracy, work-in-process optimization, and on-time delivery.
This solution integrates real-time data and predictive analytics into operations connecting directly to both ERP and machines.
Key Features and Benefits
- Dynamic Schedule Optimization: Continuously assesses and adjusts production schedules based on real-time operational data, dynamically adapting the schedule to address machine downtimes and other production interruptions.
- Real-Time Adjustments: Visualizes your scheduled OTD targets and predicts completion dates in real-time.
- Interactive Production Order Management: Users can easily edit and re-sequence production orders through an intuitive drag-and-drop interface, with immediate feedback on schedule health.
- Real-Time Impact Analysis: The system flags potential delays and adjusts work-in-process calculations dynamically, enabling proactive schedule management and empowering plant managers to make smart decisions based on real data.
- ERP Data Utilization: Integrates seamlessly with ERP systems to use planned start dates and cycle times as reliable baselines for adjustments.
by Gary Mintchell | Sep 12, 2024 | Cloud, Manufacturing IT, Operations Management, Software
I seldom do case studies here. I don’t have time to do a proper set of interviews that would emphasize team rather than product. This one came from Rockwell Automation’s company Plex. Gathering appropriate data and displaying it in ways that boost decision making constitutes a recurring problem for operations management. This story details establishing real-time reporting, insight into inventory tracking, and visibility across production.
The client company, Advanced Vehicle Assemblies, LLC (AVA) is known for its unique, complementary manufacturing processes that enable the production of complex metal assemblies. Founded in 2021, AVA has expanded significantly and now ships approximately 52.2 million parts annually.
The problem statement from AVA CIO Rob Arrowsmith: data was not easily accessible, and functions difficult to learn.
The result: real-time data is accessible, and online learning resources are abundant and easy to follow.
[Note: what follows was written by Plex marketing. I did not edit out all the adjectives and adverbs. It is a good story of actually implementing a complex software application in a short amount of time.]
AVA split from its former sister company in June 2020 and this transition kicked off an urgent search for a new ERP system. They were temporarily covered under a shared service agreement from their previous affiliation, but the end date was nearing. As a result, the company looked for an ERP solution that minimized hardware maintenance — a stark contrast to their previous experience — and could be implemented within their tight timeline.
Alongside the frequent maintenance required by the old ERP system, AVA also faced the fact that the old system did not include Manufacturing Execution System (MES) integration. The absence of real-time production reporting and inventory tracking led to reliance on manual processes, causing significant delays and a lack of trust in the collected data. As AVA aimed for rapid independence and organizational rebuilding following the split, the selection of a new ERP system became a critical aspect of their strategic focus.
As it navigated the landscape of ERP options during the summer of 2020, AVA conducted surveys, evaluations, and demonstrations to help identify their top priorities with the help of user feedback. Despite the tight timeframe, the culmination of this rigorous process led them to select Plex as their new ERP system in late 2020. This choice marked a pivotal step for Advanced Vehicle Assemblies, LLC as they embraced a new ERP system that promised to streamline operations, enhance efficiency, and support their journey towards becoming a thriving, independent enterprise.
Embarking on their ERP system revamp journey, AVA utilized the Milan, Michigan facility as their first Plex implementation site in December 2020. This location shared the outdated ERP system with AVA’s sister company, adding an extra layer of complexity to the transition. Knowing time was of the essence, Milan aimed to go live on Plex within 60 days.
To ensure a successful transition, AVA enlisted the support of Plex implementation services, who assigned a project manager to the Milan site. This project manager brought a deep understanding of the project’s parameters and the urgency of a rapid go-live timeframe. To bolster their efforts, the Plex team tapped on outside consultants to assist with the critical data cleansing phase as it was loaded into Plex. Employee training sessions and workshops were also prioritized, acknowledging the importance of preparing users for the impending changes.
As the go-live date loomed, an impressive collaboration unfolded, with up to seven Plex team members present at the Milan location during each shift. This emphasis on teamwork from all sides underscored the collective commitment to a successful implementation. Despite the challenge of a 60-day timeline, the Milan site successfully implemented Plex within the desired timeframe. Employees showcased resilience and adaptability as they mastered the main Plex functions, navigating the natural learning curve that comes with migrating to a new manufacturing solution.
The Plex implementation brought about a transformative wave of improvements for AVA, revolutionizing their operational landscape. One of the most notable enhancements was the establishment of real-time production reporting and inventory tracking. The newfound ability to access data in real time instilled a heightened sense of awareness of inventory for AVA, enabling employees to address issues promptly, fostering agility in their responses and elevating overall operational efficiency.
Furthermore, the implementation of Plex significantly augmented visibility across production. With operators more engaged and proactive on the shop floor, AVA witnessed quicker problem resolution. The benefits of Plex extended beyond the shop floor as it empowered AVA to successfully grow its business while maintaining a lean operational structure, minimizing the need for additional personnel to manage the Plex ERP system. Additionally, key Performance Indicators (KPIs) became more visible and dynamic, seamlessly integrating into Plex as native components rather than being extracted from external Excel sheets.
Plex also eliminated the necessity for financial consolidation software, streamlining processes and making contextual data easily available. The intuitiveness of the Plex system unlocked this accessibility, making it easy for users to navigate and find the information they need. The cloud-based nature of Plex, coupled with its highly configurable background settings, provided a foundation of flexibility that empowered AVA to continue to test and implement improvements. This adaptability positioned Plex as a transformative tool that not only met AVA’s original expectations for their ERP system but exceeds them into the present and future.
After the Plex implementation, Advanced Vehicle Assemblies, LLC has gone on a revolutionary journey marked by significant improvements across various facets of their operations. The shift from an outdated ERP system to Plex resulted not only in material improvements but also newfound capabilities and efficiencies. Perspectives have also evolved across departments, emphasizing the importance of collaboration and data utilization.
For AVA, the most significant achievement with Plex has been the ability to attain complete independence. Upon completion of the implementation, internal surveys affirmed the success of Plex as it earned high marks for reliability, speed, and ease of use. The adoption and integration of the software extends beyond that of the Milan, Michigan location, with AVA employees able to take on the remaining Plex implementations internally with little to no Plex support required on site.
As AVA looks towards the future, the success of the Plex implementation stands as a testament to the company’s resilience and adaptability, setting the stage for continued growth and operational excellence for years to come.
by Gary Mintchell | Sep 9, 2024 | Manufacturing IT, Operations Management
Quickbase, the software application platform for work management in complex industries, announced Sept. 5 the Quickbase Work Management platform for Manufacturing. Combining pre-built, customizable solutions called Pro Apps, templates, and AI-powered app building capabilities, Quickbase’s Work Management for Manufacturing addresses many of the most common data-driven use cases – including facility management, employee training, permit to work, site safety and compliance, machine maintenance and reporting, and more – all within a platform environment connecting teams, processes, and machines for a comprehensive view of operations.
I began working with manufacturing execution software a long time ago. I volunteered with the Manufacturing Enterprise Solutions Association (MESA) for more than 10 years. A consistent theme remains that MES software brings complexity along with its power. Implementing a system is not trivial. For the motivated and persistent engineers, a payoff eventually comes.
Manufacturing organization has changed significantly over the past 15 years or so. I’ve long been excited by Inductive Automation’s approach to SCADA/IoT applications. [Disclaimer: they are a long-time sponsor.]
The work management side has been a bit confusing to me. Then Quickbase approached me with an opportunity to learn more about no-code and low-code operations management software. [Another disclaimer: Quickbase compensates me for certain marketing-oriented work such as appearances on web presentations and occasional writing.] I met two customers (virtually) earlier this year. Their stories about functionality and ease of installing and updating made me excited about this segment of software again.
Anthony Offredi, Director, Customer Advisory Team at Quickbase, recently briefed me on this latest release. Key functions that Quickbase targets include maintenance, safety, project management for new product introduction, and shop floor management. One pain point for manufacturers concerns labor. Recruiting has become difficult. Actually getting people to show up for work every day exacerbates the problem.
I brought up the common knowledge that many companies still rely on Microsoft Excel managing everything on spreadsheets. He acknowledged that indeed Excel is a main competitor when they are presenting to a prospect.
(Aside: I’ve been preaching this for 20 years. I can’t believe that engineers and managers are trying to manipulate complex spreadsheets attempting to manage human and asset performance.)
“Industries like manufacturing, where physical work meets digital processes, demand a new class of specialized solutions built for their needs,” said Ed Jennings, CEO of Quickbase. “The stakes for safety, compliance, and productivity are too high, and these industries can’t afford to live in a world of paper forms and disconnected spreadsheets, data, and systems. Our Work Management platform is designed specifically for the unique needs of manufacturers, solving their most common challenges right out of the gate with pre-built apps and templates developed in concert with feedback from our customers. Combining the specialization of point solutions, the confidence of a connected platform, and the flexibility of easy-to-use AI-powered no-code tools, Quickbase can support the modernization of manufacturing to deliver impact every day.”
Quickbase Work Management for Manufacturing comes complete with pre-built, ready-made solutions, called Pro Apps, and app templates for some of the more common, data-driven use cases in manufacturing – including facility management, employee and site safety and compliance, and maintenance and reporting – that are easily customizable to connect teams, processes, and machines for a comprehensive view of operations. Along with those Pro Apps are a collection of templates that include prefab tracking, computerized maintenance management systems (CMMS), plant/project tracking and reporting, human error root cause analysis (HERCA), and permit to work tracking.
In addition, Quickbase’s Smart Builder AI gives manufacturers (regardless of technical expertise) the power to build their own custom apps with just a few clicks. Now, manufacturers can build a customized system of applications and workflows in a single platform environment, unlocking agile and connected operations and elevating efficiency, increasing adaptability, and boosting productivity today and into the future.
Available today, Quickbase Work Management for Manufacturing’s pre-built solutions include:
- SFMS (Shop Floor Management Solution) Pro App – Ensure the right person is in the right job at the right time, enhancing the capabilities of the existing workforce to help manage the labor shortage and skills gap, solve for absenteeism, share tribal knowledge, and increase efficiency and throughput, enabling greater visibility on labor, productivity, and scrap tracking.
- Site Safety Audits Pro App – Promote a safer work environment, reduce accidents, and ensure the highest safety standards using a streamlined process for conducting safety audits on the shop floor for inspections, hazard identification/remediation, and regulatory compliance using real-time reporting, photo documentation, and automatic generation of audit reports.
- OSHA Incident Tracking and Recordkeeping Pro App – Elevate your safety posture from reactive to proactive by automating incident reporting and tracking compliance activities, eliminating the lost time and resources (aka, Gray Work) from the inefficient logging and manual tracking of incidents, defect reporting, corrective actions, and compliance documentation across notebooks and disconnected spreadsheets, and promoting a more efficient and safer workplace.
by Gary Mintchell | Aug 29, 2024 | Manufacturing IT, Operations Management, Software
The last software update of Ignition from Inductive Automation before the Ignition Community Conference coming up in September offers several interesting enhancements.
- Gateway Trial Status Indicator—a persistent indicator in the designer to keep you informed about the status of your Gateway’s trial mode.
- Mitsubishi Driver Configurable Settings—you can now configure MELSEC Access Route settings in the Mitsubishi Driver.
- New Response Mode For OAuth2 & OIDC—a more secure way to receive authorization responses with an additional supported response type for both OAuth2 and OIDC identity providers. Now, you can accept the response_mode of form_post from both of these identity providers through your web browser.
- Development License Banner—Now, when an Ignition development license is active, there will be a banner displayed on Gateway web interface pages to alert you to that.
- EAM & Redundancy—the -Dignition.redundancy.restoreFileTTL Java additional parameter, so you can control the TTL of restore files created by backup/restore operations (including redundancy) on disk. Now, you have the ability to specify a minute value, in order to accommodate Gateways that exceed that timespan in their shutdown/startup cycle.
- Gateway Performance Monitor Logger—added a logger to Gateway.PerformanceMonitor, which the IA Support Team will be able to use to speed up your troubleshooting process if your CPU monitoring visuals start behaving strangely. Support will be able to help you turn this logger to TRACE and see exactly what your elapsed, systemTime, and lastSystemTime variables look like.
by Gary Mintchell | Aug 13, 2024 | Manufacturing IT, Operations Management
I wrote about my interview with Pico MES CEO and founder Ryan Kuhlenbeck a few days ago. He evangelizes for a resurgence of manufacturing in America. His company provides a different look at MES—low-code/no-code and starting with the tools and building up rather than a top-down complex software application requiring large expenditure and a bevy of consultants.
He hinted at this release during our talk. He cites budgetary constraints as a major impediment to many companies adopting digitalization of their processes.
From their blog post:
To restore U.S. manufacturing as a global leader in productivity, bold changes are required. That’s why starting today, all manufacturers will be able to use Pico MES’ digital work instruction suite of tools for free. Every manufacturer who signs up will receive a cloud-based instance with capabilities to build worker guidance instructions, create digital process flows, and assign stations. The only restrictions will be on the number of stations and operators (we’re not a charity, larger factories can pay a nominal fee), and the data tools that drive up our costs.
This is not a free trial with a time limit. This no-cost model supports our mission of modernizing the supply base and taking cost out of the equation.
The more frictionless an application, the more likely it will be used (speaking from harsh experience).
Our goal is to make the first step of a factory’s digitization journey as frictionless and scalable as possible without leading to a dead end. Digital work instructions are a key component when initiating this transformation. By offering these solutions for free, we are furthering our mission to make factory modernization standard within the sector.
And a further explanation.
One of the easiest ways to drastically reduce human variability is to give all operators a set of standardized work instructions with images and videos to guide their step by step processes. This then becomes interactive operator guidance that’s engaging and enjoyable while impacting retention. It becomes a teacher, ensuring the right information is present at the right time. Pico users then tie those instructions into connected tools and business systems, further amplifying gains and ensuring true continuous improvement.
Does it actually work? Case study.
Tier 1 auto supplier passes safe launch in 2 weeks
Pollington Machine Tool is a family-owned contract manufacturer with fabrication, metalworking, and final assembly capabilities that serves customers in aerospace, defense, and automotive. Recently, the company became a Tier 1 automotive supplier for an electric vehicle OEM. It was apparent that passing the safe launch qualification phase with traditional paper-based work instructions was going to be a challenge.
To pass the safe launch qualification, Pollington needed to manufacture 4,000 assemblies with zero defects – 2,000 for the left side and 2,000 for the right. Essentially, they had to prove a consistent, repeatable process for production. However, after three months of trying, they had not yet succeeded.
Pollington manufacturing engineer Chris Stewart said, “We’d complete hundreds of assemblies only for one to be missing a clip. That reset the counter to zero, and we’d start over to assemble 2,000 units.” Paper instructions in physical binders proved insufficient for operators to learn and be consistent in building complex assemblies.
To complicate things more, skilled labor is difficult to find in the tiny town of Marion, Michigan (approximate population of 900 people). Pollington relied on Spanish-speaking factory operators with an onsite interpreter. Despite having a well-documented process, improvements were needed to expedite the completion of the safe launch as production volumes ramped up.
There was also a need to improve traceability for faster response, in the event of a quality concern. Engineering Manager Brian Priddle said, “As a Tier 1 in automotive, you must have tight traceability. If there’s a quality concern, you need to be able to react very quickly to identify and isolate those parts. The OEMs need answers in minutes to keep their production lines running.”
Stewart added “Through the old way of doing everything on paper, it’s kind of hard to find the information you need if there are questions.” Searches could take hours.
Pollington implemented digital work instructions from Pico MES. The software easily uploads images with annotations and video explanations along with translated work instructions, guiding Pollington’s operators through each step of the side rail assembly. Before advancing to the next operation, the software verifies that all torque values and sequences have been followed. Stewart said, “It is easy to follow along with the instructions. You could build the assembly without any prior training.”
Visual worker guidanceThe visual worker guidance prompts the factory operator on what to do next, and if they are building product correctly. It is a gatekeeper in the background, and not disruptive to their daily flow of things.
For its pilot station, Stewart said, “We spent about a week developing our system. Then, we spent two to three days making sure everything was in place, including training. In less than two weeks, we were analyzing the manufacturing data.”
Priddle said, “With Pico’s digital work instructions, we were able to pass the safe launch within 2 weeks. That was a big deal.”
In the past 12 months, Pollington’s digital transformation has been substantial:
- Connected 18 workstations
- Digitized 100 processes and migrated from paper instructions for assembly processes
- Integrated 56 tools into the assembly process for error-proofing and traceability
