Article | December 8, 2021
The manufacturing production schedule is a critical aspect that enables the manufacturing business to complete each production activity precisely and on time. Allocating different raw materials, resources, or processes to distinct project phases is called a production schedule. Its goal is to make your manufacturing process as efficient and cost-effective as possible in terms of resources and labor — all while delivering products on schedule.
As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity."
– Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca
So, how is the overall production schedule managed?
According to businesswire, the global APS (Advanced Production Planning and Scheduling) software market was valued at $1,491.22 million in 2020 and is anticipated to raise $2,941.27 million by 2028 expanding at an 8.86 percent CAGR from 2020 to 2028.
Some software and tools are available to assist manufacturing organizations in properly scheduling production planning, including MaxScheduler, TACTIC, MRPeasy, and Gantt charts. Though there are numerous software programs available on the market for production scheduling, the most crucial aspect is determining which elements to consider when planning production.
This blog will look at the five most important factors to consider while planning the production schedule.
Five Elements to Consider When Scheduling Production
As we saw in the introduction, production scheduling is used in the manufacturing process to assign plant and machinery resources, schedule human resources, plan production processes, and purchase materials.
So, what are the primary components or stages of this production scheduling process? Let's take a quick look at each of them.
Planning to Make the Best Use of the Company's Resources
The role of planning in production scheduling is to use the company's resources to maintain a regular production flow. As a result, downtime is decreased, and bottlenecks are minimized, allowing production to be optimized. For production scheduling, two forms of planning can be used:
Dynamic Planning: Dynamic planning is carried out under the idea that process stages will alter. So, materials must be ready, but production cannot begin until demand is decided.
Static Planning: Static planning is done keeping in mind that all process steps will be completed on schedule and without adjustments.
Routing to Determine the Order of Actions
A “bill of materials” is used in discrete manufacturing to specify what things are needed and in what quantities.
Routing determines the path and sequence of required phases of the process. It may involve in-house operations, but it may also comprise sub-contracted components that must be returned to the production flow for final assembly.
Scheduling to Make Use of Predetermined Planning Levels
To manufacture products from components or raw materials, scheduling makes use of the previously set planning level. As a result, it is time-dependent and must meet the demand outlined at the planning level.
Each department, product, and procedure can have their own unique set of timetables. Sub-schedules for sub-assemblies or mixes and blends may be defined by department-specific master production schedules, utilized at the highest level to define product timeframes.
Dispatching to Decide on Immediate Actions
Dispatching assigns the following jobs to be done from a subset of the production queue. Dispatching is utilized to make quick decisions. This is in contrast to planning, which involves the planning of future actions. Dispatching is utilized in both pull and push production systems.
Execution to Ensure that all Processes are Carried out Correctly
Production scheduling must rely on proper execution to ensure that all processes are completed appropriately and in the sequence planned.
It requires everyone to know what they are expected to do and when they are expected to do it. Execution requires knowledgeable management decisions, well-trained employees, correct data in the manufacturing plan and schedule, and consistent sales statistics and forecast numbers. All must be present for the organization to carry out its production plan and fulfill orders.
How MRPeasy – A Production Scheduling Software Assist Manufacturing Companies in Scheduling Their Production?
MRPeasy is a cloud-based material requirements planning (MRP) application explicitly designed for small manufacturing units. Its primary functions are purchase order management, forecasting, and inventory management.
This software simplifies the process of scheduling production. It enables you to evaluate all of your anticipated manufacturing orders (MO). The bill of materials (BOM), purchasing, and stocking are all maintained in one location, allowing you to quickly book inventory and increase purchase orders (PO) for acquired parts.
MRPeasy enables you to:
Obtain all of the detailed information on all of your MOs
Consider MOs as a single block or as distinct operations.
Drag-and-drop operations and operations to reschedule
Calendar or Gantt chart views are available for monitoring scheduled orders.
Additionally, you can manage MOs smoothly. With the production planning component, you may create, amend, and update MOs. This app compiles an exhaustive list of all your MOs. You can track their progress based on the status of an order or a part's availability. Additionally, you can search for, filter, and export your MOs.
How to schedule production for your organization requires extensive research, planning, and analysis of overall product demand as well as a grasp of the time required to meet the demand. Production scheduling techniques such as job-based planning, batch method, flow method, and others help develop a productive manufacturing production schedule. Include the elements mentioned above in your manufacturing scheduling to get the best possible benefits, such as better production efficiency, lower production costs, and on-time product delivery for your manufacturing in 2022.
How production planning differ from production scheduler?
Production planning and scheduling are often mixed. But there is a difference. Planning decides what and how much work must be done, whereas scheduling specifies who and when the work will be done.
What is real-time manufacturing scheduling?
Real-Time Scheduling is a production planning, scheduling, and tracking tool that enables manufacturing organizations to improve customer satisfaction and achieve optimal operational performance cost-effectively.
How can scheduling be improved?
Communication with staff is a great way to improve scheduling. This is true for all businesses, software or otherwise. However, management should not burden employees with ambiguous or unclear communication, and vice versa.
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"text": "Production planning and scheduling are often mixed. But there is a difference. Planning decides what and how much work must be done, whereas scheduling specifies who and when the work will be done."
"name": "What is real-time manufacturing scheduling?",
"text": "Real-Time Scheduling is a production planning, scheduling, and tracking tool that enables manufacturing organizations to improve customer satisfaction and achieve optimal operational performance cost-effectively."
"name": "How can scheduling be improved?",
"text": "Communication with staff is a great way to improve scheduling. This is true for all businesses, software or otherwise. However, management should not burden employees with ambiguous or unclear communication, and vice versa."
Article | November 23, 2021
Having recently returned from Uganda, had the pleasure of being introduced by Bernard Munyanziza of Nziza Hospitality to Gilbert Atuhire. He is the Managing Director at Value Addition Microfinance Ltd. which provides micro loans to producers and manufacturers.
Atuhire is an attorney by training, however his ability to articulate the core values of Lean Six Sigma and continuous process improvement were abundantly clear. The Kampala, Uganda offices are located on Parliamentary Avenue and Dewinton Rise. This central location allows direct access to industrial projects.
Article | March 1, 2022
Industrial IoT (IIoT) is an abbreviation for the Industrial Internet of Things, originally defined as the Internet of Things (IoT). It is utilized across industries, including manufacturing, and shows great positive results, supporting overall business growth.
According to Grand View Research, globally, the industrial internet of things market size was worth around $216.13 billion in 2020 and is predicted to reach over $1.1 trillion by 2028. Is IIoT similar to IoT? The answer is yes.
“If you think internet has changed your life, think again. The internet of things is about to change it all over again.”
– Brendan O’Brien
Like the Internet of Things, the Industrial IoT has multiple use cases and applications. Additionally, the Industrial Internet of Things (IIoT) opens up new opportunities in multiple areas. Some of the industrial internet of things examples are as follows:
The Internet of Things industrial automation and optimization
Intelligent manufacturing and smart industries
Asset performance management and industrial control
Moving towards an on-demand service model
New ways of servicing customers
New revenue streams
Internet of Things Industrial Applications
According to IDC, manufacturing operations are the primary use case for the IoT in manufacturing. In this article, we'll look at five particular IIOT applications in manufacturing operations, production asset management, and field services that are driving Industrial IoT adoption in manufacturing.
Industrial IoT can link machines, tools, and sensors on the shop floor, providing much-needed visibility into production for process engineers and management. For instance, businesses may use sensors like RFID and break beams to track components as they travel through assembly automatically. Additionally, industrial IoT apps may provide supervisors and plant managers with a real-time picture of their teams' yield by linking operators’ tools and production equipment. Organizations may utilize this degree of visibility to detect bottlenecks, determine the main cause of issues, and improve more rapidly. Dashboards for real-time IIoT production visibility can help businesses find problems and track productivity in real-time.
Continuous Monitoring for Quality Improvement
Environmental sensors continuously monitor necessary quality conditions and notify management when crucial quality thresholds exceed permissible limits. For instance, temperature control is crucial to pharmaceutical manufacturing. By utilizing IoT-connected sensors, managers may monitor temperature and humidity and receive quick alerts if they deviate from expected values. Continuous monitoring, similar to machine monitoring, can help you keep an eye on your assets in real-time.
Maximize Machine Use
The Industrial Internet of Things enables businesses to link their machinery to the internet. This technology enables organizations to monitor their machines in real-time while also tracking critical KPIs such as overall equipment effectiveness (OEE) and overall process effectiveness (OPE). By monitoring these indicators, businesses may discover and resolve sources of unscheduled downtime, perform preventive maintenance on their equipment, and maximize machine used throughout the operation. According to a recent McKinsey article, sensor data used to forecast equipment failure in production may reduce maintenance costs by up to 40% and unscheduled downtime by half. So, by applying IIoT, you may monitor the key performance indicators (KPIs) that are most important to you.
Improve Plant Management
Using sensors in production plants may enhance their management and minimize the operating expenses of a plant. For example, by employing sensors such as RFID tags to monitor facilities, manufacturers may gather insights to help them optimize space consumption. Using IoT-enabled sensors to monitor environmental factors like temperature, humidity, and others may also help firms better manage their buildings. Finally, businesses can save energy, cut costs, and improve operational efficiency by keeping an eye on their machines and making sure they are running in the right conditions.
Optimize Supply Chain Management
The Internet of Things enables sensors to monitor events across a supply chain, delivering real-time data by tracking inputs, equipment, and products. RFID tags and other sensors can track inventories throughout the supply chain. This gives businesses a better understanding of their inventory and more realistic deadlines for material availability, work in progress, and others. Organizations may use this data to detect interdependencies, map material flow, and monitor production cycle durations. This data aids businesses in predicting risks. It also lowers inventory levels and, perhaps, capital requirements. No code tables hold all of your inventory data. Tables are automatically updated as inventory is consumed during operations.
Industrial Internet of Things vs Internet of Things (IIoT Vs IoT)
It is geared for industrial applications such as manufacturing, power generation, and oil and gas.
It focuses on a broad range of applications, from wearables to robotics and machinery.
To avoid life-threatening or other emergency circumstances, it employs crucial equipment and gadgets connected through a network that requires precise sensors.
Its deployment begins on a modest scale, eliminating the possibility of life-threatening scenarios.
It deals with extensive networks.
It deals with modest networks.
It is capable of processing data ranging from mild to high.
It is capable of processing enormous amounts of data.
It is highly reliable.
It is less reliable.
IIoT Adoption Challenges & Solutions
Significant investment expenses are necessary to transform operations, including hardware, software, and human capital. Businesses frequently view IIoT as a giant leap ahead, resulting in a massive bill. A more effective strategy is to break the projects down into bite-sized implementations with set milestones. This will pave the way for outcome-driven success that can be quantified by top-tier management, resulting in a more passionate reaction and maybe a larger scale resource limitation.
Additionally, expenses can be reduced by utilizing public infrastructure and software-as-a-service rather than custom-built installations. While the cost of IoT continues to decline, numerous organizations' executives are playing the waiting game. This strategy may be good for the short term, but if you wait for prices to go down for a long time, you ccoul lose your competitive advantage and let other people get a better deal.
It's easy to get paranoid about the attacks and problems because of all the news about cyber security. One must address these security concerns methodically and recognize measures to secure critical industrial information. Depending on the level of sensitivity, data can be checked and encrypted using a variety of one-way interactions. SCADA systems do not have to combine and act on sensor data; they can be digitally segregated. Additionally, the cloud infrastructure might be networked inside to create a "private" or corporate cloud with no external access. These security challenges can be surmounted if the advantages of the IIoT outweigh the hazards.
Lack of Skilled Professionals
While it is true that the digital world is rapidly merging with the industrial world, the issue remains as to who in the organization can take charge. An individual or team must bridge the IT and OT cultures and meet opposing demands. The program requires a blended IT/OT viewpoint to achieve IIoT goals while increasing operational complexity and responsibilities.
There are several data science certifications, online courses, and conferences available to educate middle management. Start growing competency while making learning and education a management team KPI. Consider partnering with institutions and educational vendors. The executive team's appetite for knowledge must be continual. Learning will be viewed as a lifetime process requiring dynamic stability and continual mobility.
A shortage of competent personnel was also stated in the Morgan Stanley-Automation World Industrial Automation Survey, with 24% of respondents citing a labor shortage. There is a general shortage of highly specialized talents, but it may also be necessary to look 'outside' to get the essential skills. If there is one thing that is certain in this age of digital transformation and the Industrial Internet of Things, it is that no organization can flourish entirely on its own and that networks, ecosystems, and platforms of partners are critical to success.
Starting an IIoT project should be done with a straightforward and practical approach. This is not a big company-changing initiative, but a series of small projects or digital test beds that might raise sales, profits, or customer retention. Read our latest industrial internet of things infographic for quick tips on tackling IIoT adoption issues.
What are IIoT devices?
IIoT refers to linked sensors, instruments, and other devices networked with industrial applications like manufacturing and energy management.
What is an IIoT platform?
Gartner describes IIoT platforms as a collection of integrated software capabilities. The platform is designed to support industrial assets and their operational environments in safety, security, and mission criticality.
What is the IoE?
The Internet of Everything (IoE) is a concept that builds on the Internet of Things (IoT). It focuses on machine-to-machine (M2M) connections to represent a more complicated system that includes people and processes.
Article | February 21, 2022
Nanomanufacturing is a revolutionary way to make things that enables manufacturers to do more than they thought was possible. Faster, stronger, lighter, cheaper, and more durable are essential attributes for production. On the other hand, nanotechnology in manufacturing also makes things water-resistant, anti-reflective, self-cleaning, ultraviolet or infrared resistant, antibacterial, scratch-resistant, and electrically conductive, among other things.
“Nanotechnology is the idea that we can create devices and machines all the way down to the nanometer scale, which is a billionth of a meter, about half the width of a human DNA molecule.”
– Paul McEuen, an American physicist
With nanoscale materials, the promise of nanotechnology to the production and the number of nanotechnology manufacturers in the industry continues to expand. Nanomanufacturing uses components 10–100 nanometers in size to improve the attributes of high-performance, next-generation goods. Some examples of nanotechnology products in everyday life are sunscreen, clothing, furniture, adhesives, tennis balls, computers, and more.
Nanomanufacturing, or the fabrication of nanoscale materials such as powders or fluids, permits high-precision production via a "bottom-up" or "top-down" approach.
Bottom-up: Building products from molecular components
Top-down: Developing products from the whole piece of component
Application of Nanotechnology in Manufacturing
Nanotechnology is utilized to develop more effective and stable lubricants, making them helpful in a wide variety of industrial applications. At the nanoscale, materials can operate similarly to ball bearings in petroleum-based lubricants, assuring smooth operation, uniform distribution, and minimizing accumulation. In addition, they can make sure that machine parts stay lubricated even if there are significant changes in temperature or pressure.
Nanotechnology is also employed in the automobile industry. Manufacturers of high-end tires are increasingly using polymer nanocomposites to boost their durability and wear resistance. Additionally, nanotechnology can be used to improve consumer automobile goods such as motor oil.
Application of nanotechnology in manufacturing enables the fabrication of microelectronics and electric devices — such as nanoscale transistors made of carbon nanotubes — in electronics. Tiny products like flexible solar panels, electric fabrics, and flexible gas sensors can be printed because they are very thin and can be made to bend.
Additionally, nanomachines or nanites—mechanical or robotic devices that work at the nanoscale—have demonstrated significant potential. Nanomachines are mostly considered futuristic technology and are not commonly employed in production at the moment. This is predicted to change in the near future. Researchers are already seeing how nanoscale, self-assembling devices can be used in a wide range of fields, most notably in medicine, where they could be used in ways traditional machines can't..
Top 3 Leading Nanotechnology Companies
Taiwan Semiconductor Manufacturing Company Ltd. offers a diverse product portfolio that serves applications in the electronics, automotive, computer, consumer, and telecommunications industries. TSM created the world's first 7-nanometer chip, which powered Apple's iPhone X. The rise in demand for low-power, high-performance CPUs results from the introduction of AI, 5G, and self-driving automobiles. TSM is now manufacturing chips at a 5-nm node and a 2-nm mode. TSM's main clients are Apple and Advanced Micro Devices.
Thermo Fisher Scientific
Thermo Fisher Scientific, Inc. is a U.S. based company that develops and sells scientific instruments, reagents, and consumables to laboratories in the life sciences and other fields. Thermo Fisher Scientific, Inc. creates electron microscopes that can efficiently zoom in on a single atom's picture. These microscopes are generally used to aid those who are creating nanotechnology or packaging nanodevices. Thermo Fisher Scientific, Inc. is a well-known company that sells scientific apparatus. It has a market capitalization of more than $185 billion.
DuPont de Nemours, Inc.
DuPont de Nemours and Company provides technology-based materials, solutions, and ingredients, and does substantial research and development in nanotechnology, chemistry, material sciences, and engineering. Dow Chemical and E.I. DuPont de Nemours and Company merged to establish DuPont de Nemours, Inc. in 2017. DuPont's extensive R&D toolbox comprises, among other things, nanotechnology, chemistry, engineering, and materials science.
The Future of Advanced Objects and Devices with Nanotechnology
Nanotechnology is a rapidly emerging field with bright prospects for the future. Many manufacturing fields, including information technology, health, military, transportation, energy, environmental science, telecommunications, and electronics, are in their transformational phase.
Aside from that, experts are looking at new ways that nanotechnology to the production might help humanity build energy sources and devise systems for accessing and using fossil resources more efficiently. The creation of large nanomaterials will result in a fundamentally different approach to the manufacture of materials and gadgets. This approach will influence every part of a person’s life.
Faster computers, advanced pharmaceuticals, controlled drug delivery, biocompatible materials, nerve and tissue repair, crack-proof surface coatings, better skin care and protection, more efficient catalysts, better and smaller sensors, and even more efficient telecommunications are some of the areas where nanomaterials will have a significant impact.
Nanotechnology in manufacturing transforms products and qualities, making them more durable and advanced. The growth of nanotechnology is transforming every sector, along with production.
It can promote health, use natural resources more efficiently, and reduce pollution.New nanomaterials and ideas are being developed to efficiently convert energy from movement, light, temperature fluctuations, glucose, and other sources.
Technology may one day allow objects to gather energy from their environment. Nanotechnology will influence practically everyone's life in the next 20 years.
How does nanomanufacturing work?
Nanomanufacturing is the process of manufacturing nanoscale materials, structures, devices, and systems at a scaled-up, dependable, and cost-effective scale. Additionally, it encompasses the study, development, and integration of both top-down and increasingly complicated bottom-up and self-assembling systems.
What does nanotechnology do?
Nanotechnology is recognized as having the ability to boost energy efficiency, aid in environmental cleanup, and tackle severe health concerns. It is reported to increase industrial output significantly while saving costs.
How might nanotechnology help us in the future?
In the future, nanotechnology may help us improve the efficiency of electrical lines, solar cells, biofuels, and the safety of nuclear reactors. In addition, nanotechnology can revolutionize health care by enhancing ways of diagnosing and treating illnesses like cancer.