Procurement & Supply Chain
Article | January 3, 2022
Production planning and control are critical components of any manufacturing organization. It helps organizations with the regular and timely delivery of their goods. Furthermore, it allows manufacturing businesses to increase their plant’s efficiency and reduce production costs.
Numerous software and tools for production scheduling and planning are available on the market, including Visual Planning, MaxScheduler, and MRPeasy, which assist manufacturing organizations in planning, scheduling, and controlling their production.
According to KBV Research, the manufacturing operations management software market is anticipated to reach $14.6 billion by 2025 globally, expanding at a market growth of 10.2 percent CAGR during the forecast period.
So, what exactly is production planning and control?
Production planning is an administrative process within a manufacturing business. It ensures that sufficient raw materials, personnel, and other necessary items are procured and prepared to produce finished products according to the specified schedule.
Scheduling, dispatch, inspection, quality control, inventory management, supply chain management, and equipment management require production planning. Production control makes sure that the production team meets the required production targets, maximizes resource utilization, manages quality, and saves money.
“Manufacturing is more than just putting parts together. It’s coming up with ideas, testing principles and perfecting the engineering, as well as final assembly.”
– James Dyson
In oversize factories, production planning and control are frequently managed by a production planning department, which comprises production controllers and a production control manager. More significant operations are commonly monitored and controlled from a central location, such as a control room, operations room, or operations control center.
Why Should You Consider Production Planning?
An efficient production process that meets the needs of both customers and the organization can only be achieved through careful planning in the early stages of production. In addition, it streamlines both customer-dependent and customer-independent processes, such as on-time delivery and production cycle time.
A well-designed production plan minimizes lead time, the period between placing an order and its completion and delivery. The definition of lead time varies slightly according to the company and the type of production planning required. For example, in supply chain management, lead time refers to the time required for parts to be shipped from a supplier.
Steps in Production Planning and Control
Routing
The first stage of production planning determines the path that raw materials will take from their source to the finished product. You will use this section to determine the equipment, resources, materials, and sequencing used.
Scheduling
It is necessary to determine when operations will occur during the second stage of production planning. In this case, the objectives may be to increase throughput, reduce lead time, or increase profits, among other things. Numerous strategies can be employed to create the most efficient schedule.
Dispatching
The third and final production control stage begins when the manufacturing process is initiated. When the scheduling plan is implemented, materials and work orders are released, and work is flowing down the production line, the production line is considered to be running smoothly.
Follow-Up
The fourth stage of manufacturing control ascertains whether the process has any bottlenecks or inefficiencies. You can use this stage to compare the predicted run hours and quantities with the actual values reported to see if any improvements can be made to the processes.
Production Planning Example
Though production planning is classified into several categories, including flow, mass production, process, job, and batch, we will look at a batch production planning example here.
Manufacturing products in batches is known as "batch production planning." This method allows for close monitoring at each stage of the process, and quick correction since an error discovered in one batch can be corrected in the next batch. However, batch manufacturing can lead to bottlenecks or delays if some equipment can handle more than others, so it's critical to consider capacity at every stage.
Example
Consider the following example of batch production planning:
Jackson's Baked Goods is in the process of developing a production plan for their new cinnamon bread. To begin with, the head baker determines the batch production time required by the recipe.
He then adjusts the bakery's weekly ingredient orders to include the necessary supplies and schedules the weekly cinnamon bread bake during staff downtime.
Finally, he creates a list of standards for the bakery staff to check at each production stage, allowing them to quickly identify any substandard materials or other batch errors without wasting processing time on subpar cinnamon bread.
Final Words
Running a smooth and problem-free manufacturing operation relies heavily on a precise production planner. Many large manufacturing companies already have a strong focus on streamlining their processes and making the most of every manufacturing operation, but small manufacturing companies still have work to do in this area. As a result, plan, schedule, and control a production that will enable you to run your business in order to meet its objectives.
FAQ
What is the difference between planning and scheduling in production?
Production planning and scheduling are remarkably similar. But, it is critical to note that planning determines what operations need to be done and scheduling determines when and who will do the operations.
What is a production plan?
A product or service's production planning is the process of creating a guide for the design and manufacture of a given product or service. Production planning aims to help organizations make their manufacturing processes as productive as possible.
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Manufacturing Technology
Article | June 2, 2022
Over the last few years, additive manufacturing (also known as 3D printing) has garnered much attention and appreciation, both from consumers and the manufacturing fraternity. 3D printing, which started as a prototyping technology, has come a long way since its inception. To put it in simple words, additive manufacturing (AM) is a game-changer for manufacturers of all sizes.
Traditional ways of generating products such as machining, cutting, turning, shaping, milling, and other "subtractive" manufacturing processes can be supplemented, and in some circumstances, completely replaced, by additive manufacturing. When we look at the bigger picture, AM is transforming people’s lives, which includes but is not restricted to just medical advances, safer transportation, highways, or any other infrastructural developments.
Manufacturers can now swiftly make mock-ups of a new product or a part to fulfill a specific market niche, which can lead to the production of high-profit margin products. When additive manufacturing is used from start to finish, the overall manufacturing process becomes even more streamlined.
Given the advantages of AM, it's only natural that the technology would be used in the aerospace industry. According to MarketanndMarkets, aerospace 3D printing is expected to exceed $3 billion by 2022 due to the rising demand for lightweight 3D printed parts for aircraft engines.
Here are some areas where AM is implemented in the aerospace industry.
Constructing Rocket Bodies:
Relativity Space is a California-based aerospace manufacturing firm that focuses on creating manufacturing technologies, launch vehicles, and rocket engines for commercial orbital launch services. Their Stargate manufacturing facility is known to house the world's largest 3D printers. These printers use direct energy deposition and patented alloys to make the outer bodies of their rockets.
When compared to traditional launch vehicles, 3D printing allows them to quickly create integrated components with a 100-fold lower part count. This also reduces weight and increases reliability, both of which are critical to the economics of space launch. It further allows designers to explore numerous designs in a short time span and helps enhance the overall quality and arrive at a better design.
Designing Rocket Engines:
Rocket Lab is a public American aerospace company that specializes in small satellite launches. Their Rutherford rocket engine was first tested in late 2016, and over 200 of these game-changing variants have been manufactured since then.
The combustion chambers, injectors, pumps, and main propellant valves of this engine were all 3D printed utilizing electron-beam melting. The resulting engine is simple, dependable, and light, weighing only 35 kg (77 lb), making it perfect for low-cost space launches. Their new Curie and HyperCurie thrusters, which operate outside Earth's atmosphere, are based on the same principles.
Designing Astronaut Outfits:
Additive manufacturing isn't just for making actual rockets; it may also be used to create improved, refined astronaut outfits. The costumes of SpaceX's crew were partially produced with additive manufacturing when they sent humans into space.
Even though the company has kept much of the underlying technology under wraps, a source shared that the helmet was made by using 3D printing technology and it had integrated valves, visor retraction and locking mechanisms, and microphones built into the structure.
Wrapping Up:
The current pace of manufacturing and engineering really necessitates the need for everyone to invest in additive manufacturing.”
Cory Larson WMEP Manufacturing Solutions Consultant – Automation & Cybersecurity, Registered Practitioner, CMMC-AB
AM is also gaining traction in the commercial manufacturing and fabrication markets. Metal fabrication companies all around the world have begun to provide additive manufacturing solutions in addition to subtractive methods like CNC machining. 3D printing is swiftly becoming one of the cornerstones of the industry 4.0 movement due to its capacity to generate high-tolerance parts and rapid prototypes at a substantially reduced cost.
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Industrial 4.0
Article | June 16, 2023
Explore the current state of the production and manufacturing industries and discover how it achieves re-industrialization of the former industrial powerhouses counterbalancing the benefits.
Below is the guide to Industry 4.0 library, a curated collection of insightful and captivating reads designed to equip professionals with the knowledge and strategies needed to excel in today's rapidly evolving business landscape. This carefully selected list presents ten must-read books that delve into the fourth revolution of digitalization, exploring the transformative power of emerging technologies, automation, and data-driven decision-making. Whether you are a seasoned industry expert or a curious newcomer, these compelling titles offer invaluable insights into mastering efficiency, driving innovation, and staying ahead in the age of Industry 4.0 through practical scenarios and case studies. Prepare to embark on a journey of discovery and unlock the secrets to thriving in the digital revolution.
1. Industry 4.0 The Industrial Internet of Things
Author: Alasdair Gilchrist
Industry 4.0 The Industrial Internet of Things delves into the current production, processing, and manufacturing status and examines the requirements for re-industrializing former industrial powerhouses. Titled 'Industry 4.0: The Industrial Internet of Things' is the book that focuses on Industry 4.0, a concept encompassing emerging trends and technologies that can revolutionize the current manufacturing and production processes. It explores the potential of advanced technologies such as the internet of things, big data, cyber-physical systems, and smart factory systems to replace the traditional labor-intensive approaches prevalent in offshore locations. Key topics covered in the book include Identifying the technological advancements for enabling Industry 4.0 and exploring the ongoing efforts, applying insights from real-world case studies to practical scenarios. Being one of industrial revolution books, this book caters to a broad audience, including business futurists, business strategists, CEOs, CTOs, and individuals and anyone interested in understanding the future development of IT.
2. The Fourth Industrial Revolution
Author: Klaus Schwab
The author, an economist,the Founder and Executive Chairman of the World Economic Forum, asserts that we are on the cusp of the fourth industrial revolution, a transformative era with profound implications for our lives and work. The presence of artificial intelligence, manifesting in supercomputers, drones, and virtual assistants, along with 3D printing, DNA sequencing, and minuscule microchips, are only the early stages of the revolution. Imagining ‘smart factories’ where global manufacturing systems are virtually coordinated or implantable mobile phones made from bioengineered materials provide a glimpse into the future. Schwab outlines the technologies driving this revolution and discusses the significant impacts expected on businesses, civil societies and individuals. He further presents innovative ideas on leveraging these changes to create a better future where technology empowers people instead of replacing them, progress benefits society rather than disrupts it, and innovators uphold moral and ethical boundaries.
3. Artificial Intelligence and Industry 4.0
Author: Jyotir Moy Chatterjee
The book Artificial Intelligence and Industry 4.0 book examines the recent advancements in blockchain technology and artificial intelligence and their significant contributions to realizing Industry 4.0 objectives. It delves into the applications of AI in various industries, particularly the Internet of Things and Industrial Internet of Things technologies. The chapters cover a wide range of topics, including machine learning, smart cities, healthcare, and Society 5.0, exploring the numerous potential applications of AI in the context of Industry 4.0. This book is a resource for computer science researchers and graduate students involved in developing and studying AI and the IIoT. The key features of the book include exploring the application of AI in the industrial manufacturing sectors and presenting examples of ML, computer vision, and digital twin applications in the IoT industry. It further explains examining the facilitation of processing of large datasets, accurate risk forecasting, and the generation of recommended actions through deep learning and cognitive computing tools.
4. Handbook of Industry 4.0 and SMART Systems
Author: Diego Galar Pascual, Pasquale Daponte, Uday Kumar
One of the books on Industry 4.0 is the Handbook of Industry 4.0 and SMART Systems explores the concept of Industry 4.0, which represents the fourth generation of industrial activity marked by the integration of smart systems and internet-based solutions. It delves into the various technologies and methodologies that have contributed to this revolution, highlighting the importance of instrumented, interconnected, and intelligent assets. The chapters provide insights into the advancements and implementation of Industry 4.0, with a specific focus on the role of smart systems in maintenance to enhance performance, productivity, and flexibility. Additionally, the book explores the applicability of Industry 4.0 in sectors such as transportation, energy, and infrastructure, examining the impacts on technology, organizational structures, and operational aspects from a systems perspective.
5. Industry 4.0 Developments Towards the Fourth Industrial Revolution
Author: Kaushik Kumar, Divya Zindani, J. Paulo Davim
The book on Industry 4.0 Developments Towards the Fourth Industrial Revolution offers a comprehensive introduction to the emerging field of Industry 4.0, which is poised to revolutionize manufacturing by combining flexibility, enhanced communication, increased productivity, and improved product quality. It provides a management holistic overview of risk, intelligent manufacturing, product development, covering process planning, assessment, education and qualification needs, socio-technical considerations, and sustainable business models. Engineers, entrepreneurs, academics, and students engaged in the information technology and manufacturing fields will find this volume valuable as it addresses various aspects of Industry 4.0 and its implications for the industry's future.
6. Introduction to Industrial Internet of Things and Industry 4.0
Author: Sudip Misra, Chandana Roy, Anandarup Mukherjee
One of the Industry 4.0 book, this book is designed to cater to the growing interest in Industrial IoT and Industry 4.0 among students, researchers, and professionals in various engineering disciplines. It serves as a textbook and a reference guide, covering the essential aspects of IIoT, including sensors, actuators, data transmission, and data acquisition, fundamental to its functioning. Moving beyond the basics, the book delves into advanced topics, such as the business models and reference architecture of IIoT, predictive and prescriptive analytics in IIoT implementations, the technological aspects of Industry 4.0 and IIoT, real-world applications and case studies, and the key enabling technologies of IIoT. To enhance the learning experience, the book includes conceptual exercises, questions, and learning objectives, making it a valuable resource for students and professionals seeking to master the concepts and applications of IIoT and Industry 4.0.
7. Navigating Industry 4.0
Author: Parasnis, Ashutosh
One of the industrial revolution books, Navigating Industry 4.0, provides manufacturers with a clear understanding of Industry 4.0 and a systematic approach to its implementation. Readers can optimize resource allocation by focusing on relevance and avoiding non-value-added activities. The book guides them in developing digitalized business strategies and builds the necessary execution capabilities. Additionally, it enables manufacturers to visualize and design their tailored strategies and roadmaps, eliminating waste of time and money. The author, an experienced keynote speaker, electronics engineer, and MBA specializing in marketing, and strategic management, activates critical thinking and brings clarity to benefit your businesses. With over 30 years of industry expertise, his insights and guidance have assisted enterprises, SMEs, and start-ups on their transformative journeys. Engage with this book to unlock your potential in the era of Industry 4.0.
8. New - Age Technology And Industrial Revolution 4.0
Author: Narendra Jadhav
This comprehensive book delves into the emerging new-age technology that underpins the ongoing industrial revolution 4.0. It explores its profound impact on the economy, society, and public policy within a global context. In Part One, readers are introduced to the foundational elements of this technology, including AI and ML, big data analytics, robotics, blockchain, automated technology, additive manufacturing, internet of things, and augmented reality. Part Two delves into the potential implications of the new-age technology on various aspects such as economic growth, employment, the evolving landscape of banking-finance 4.0 and so on. Part Three expands upon the global public policy dimensions associated with this technology. It addresses critical issues such as the Right to Privacy, the impact of social media on democratic governance among others. This section also covers regulatory considerations and strategic developments related to the new-age technology.
9. Profiting from Industry 4.0: The road to future value in manufacturing
Author: Marcos Kauffman
The era of the fourth industrial revolution, or Industry 4.0, holds tremendous potential for performance transformation and the creation of new markets, both for established players and disruptive ventures. However, the key challenge lies in adapting to the new digital rules and capturing value through enhanced performance. This book, authored by an expert and practitioner in the field of Industry 4.0, provides invaluable tools, templates, and guidelines for manufacturers on the frontline. Drawing from a comprehensive analysis of current manufacturing contracts, it highlights essential questions for manufacturers to consider. It explores various options for managing innovation, designing business models, handling intellectual property, and ultimately gaining a sustainable competitive advantage. It offers a roadmap for navigating the complexities of Industry 4.0, empowering manufacturers to adapt, innovate, and secure their position in the evolving digital landscape.
10. Industrial Digital Transformation
Author: Shyam Varan Nath, Ann Dunkin, Mahesh Chowdhary, Nital Patel
Industrial Digital Transformation: Accelerate Digital Transformation with business optimization, AI, and Industry 4.0 the book provides insights into digital transformation and its significance in today's business landscape. Divided into two parts; the first explores the concept and importance of digital transformation, while the second part focuses on its practical implementation. Advanced topics, such as overcoming challenges and exploring the concepts of Digital Thread and Digital Twin, are covered further. The book offers a range of case studies from both private and public sectors, highlighting successful transformation strategies and resident experience improvement on a global scale. Furthermore, readers will discover how to create a practical playbook for successful digital transformation, leveraging cloud computing, big data, and the Internet of Things. The book is a valuable resource for IT leaders, digital strategy leaders, solution architects, and service and management consulting firms’ professionals.
Final Thoughts
These captivating books discussed in the article provide valuable insights and guidance for manufacturing experts in the digitalization sector. These resources cover various aspects of industrial IOT, big data, robotics, smart systems, among others. By delving into these industry 4.0 books, professionals can gain a deeper understanding of effective implementation of digitalization into productions across their infrastructure. With the ever-evolving digital landscape, staying up-to-date with the latest trends and best practices is crucial. These books offer industry-relevant knowledge and empower experts to make informed decisions and gain expertise in the relevant industries.
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Insights
Article | February 12, 2021
More and more, brands are beginning to see the value of their packaging in influencing consumers’ purchasing decisions. But much less often do they understand the true potential of their outer and additional elements in driving brand engagement, increasing loyalty and enhancing the overall customer experience – and it’s by doing the latter, you can really make consumers fall in love with not only your products, but your brand and business too.
In this article, Robert Lockyer, CEO and founder of Delta Global, a packaging solutions provider for luxury retail brands in fashion and beauty, explains why customers must love a brand’s packaging before they even begin to undress its layers and get to what’s inside.
Love at first sight
With packaging, looks do matter. In the digital age especially, that all important outer shell is often the first physical point of contact a customer has with a brand so the impression it leaves needs to be a positive one, as this will then influence consumers’ respective thoughts and feelings towards the brand and their overall experience with it.
The look of the packaging, understandably, plays a key role in making this impact. It needs to look neat, presentable and fit for purpose first of all, which will come down to the quality of materials used for example, and then in line with what they were expecting of the brand, next.
To achieve this, it’s common for packaging to carry a brand’s logo, colours or other visual cues. But while most brands have mastered this, more can be done by taking into consideration wider brand values, and then developing packaging solutions that represent them.
For instance, in recent years, an increasing number of luxury brands have adopted more minimalist images in order to represent more timeless and classic brand values, and their packaging elements have been updated to reflect such a shift. As a result, it is common for designer bags, boxes and inserts to be sleek in design, with minimal branding, often with just a name printed on them while also being in the company’s recognisable colours.
Take The White Company as an example. Whether a customer places an order online or makes an in-store purchase, there are clear preconceptions of what is to be expected from the brand’s packaging. While colour is on obvious one, customers expect the same clean, minimal and sophisticated designs present in all other branding elements to also be reflected in its packaging. And they’re not wrong.
When they receive a package from the brand, or walk out of the shop with a bag, they are left with a clear and consistent overall experience, which will then evoke positive feelings towards the company and its products, and ultimately, a repeat purchase.
Not only this, but the smart and sophisticated design of such boxes affords them greater status, and therefore use, enabling them to be used in replacement of gift wrapping and even as decorative household items.
Love is green
When packages can be reused in this way, they are also better for the environment. And with an increasing number of customers desiring greater sustainability from brands as well as ways to reduce their own carbon footprints, investing in eco-friendly packaging only does the company favours.
Ultimately, sustainability is a question of ethics, and by tapping into consumers’ deep rooted personal values by aligning their activities to them, brands can certainly encourage deeper connections and better engagement with customers. Over time, this translates to repeat purchases and even brand loyalty and advocacy, which are things all brands strive for.
The offering of sustainable packaging, therefore, becomes yet another reason for customers to choose and love a brand and its products, and going forward, this will help set certain companies apart from competitors.
Therefore, any investment will be worthwhile. With high quality packaging that meets consumers’ expectations and leaves them with a positive overall experience and feelings towards the brand, companies can encourage behaviours that only provide greater commercial value to the business, as well as protect our planet. And that certainly should not be a second thought.
An online affair
Another thing that should not be dismissed is the prominence of online retail. Unarguably, global ecommerce sales figures are on the rise, and the COVID-19 pandemic and its related disruption have only accelerated the digital-first shift.
Although not the most obvious matter, packaging has a huge role to play in ensuring products can be shipped to customers all over the world, safely and efficiently. Before a product even reaches a customer, it has likely been packed and passed around in many different ways, and by the time it does become theirs, these various packaging elements must have done their job well and enabled it to arrive on time and in one piece. If it does not, it is likely customers will have already developed unfavourable perceptions of the brand, and no matter how much they had desired the product, their experience will have been tainted and the feeling of ick will prevail.
While this is a test for the functionality of a brand’s packaging, the online route via which it has arrived at a customer’s door means brands need to think far beyond this in the digital age. As mentioned previously, in these instances, the package is often the first physical touchpoint a customer has with a brand, and as well as meeting their expectations, they also need to be impressed by what they see in order to really fall in love with their purchase.
The whole experience of receiving and opening an order needs to be just that – an experience. And while quality and functionality have some part to play in this, the real love story is created through offering customers greater value, whether that be with additional uses, higher quality materials, or personalised interactions, for example.
That last point is where there is a real sweet spot, particularly for ecommerce sales. The physical distance between customers and an online seller can drive great disconnect and have detrimental impacts on engagement. Therefore, by reinforcing the online sales journey by personalising packaging elements, this gap can be narrowed.
Personalisation in this way can be anything from tailored message cards, through to smart QR codes that take customers straight to the brand’s social media channels, for example. But whatever method is chosen, the experience must be straightforward, interactive and feel unique and relevant to each individual customer. This will allow them to get a real sense of the brand, what it stands for and exactly why they should love its products.
As it would seem, when it comes to packaging, the age-old saying isn’t true... while a package’s contents are important, as ultimately, that is what the customer has paid for, it’s what’s outside that counts.
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