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
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.
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.
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.
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.
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.
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.
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.
Article | May 18, 2021
For twenty years as an editorial contributor to Quality Digest magazine, I have had the pleasure of authoring or collaborating more than 80 articles for the publication. During this two-decade tenure, I have worked with Dirk Dusharme (pictured left), Editor in Chief of Quality Digest.
Quality Digest’s website receives more than three million page views each year, which provide editorial content, live broadcasts, videos, and on-demand webinars presented by industry experts on international quality standards, leadership, manufacturing, metrology, statistical process control, training, and more.
Quality Digest continues its important role as companies navigate a post-COVID reality with a critical role of safety, quality, efficiency, and resiliency. Quality elements are no longer an after-thought. It is essential when examining automation, lean manufacturing, and new paradigms for best practice. During COVID, all of us became more remote savvy and the demand for visionary content and information essential.
According to Dusharme, “Since their debut almost a decade ago, Quality Digest's "enhanced" webinar events have raised the bar for the traditional webinar experience. Our audience has come to expect concise, informative, and engaging presentations with subject matter experts who know what they are talking about. Apart from the traditional quality topics, we delve into areas that broaden our audience’s knowledge. These topics range from cybersecurity, to supply chain management, to understanding and dealing with cognitive biases. Our goal is to provide up-to-date, actionable information that our audience can immediately put to use. Live video feeds of the presenters and the products, interactive Q&A sessions, surveys, and valuable downloads all make up our usual webinar experience, followed by next-day access to the on-demand recording and materials.”
Enhanced Webinars from Quality Digest feature real-time streaming video of host, subject matter expert, and a case study in action. Users can email questions, chat, or download files in real-time. This modality is ideal for visual case studies/product demos, team or customer training, and new product/new service announcements.
Article | November 20, 2021
Modern manufacturing methods are pioneering and adopting manufacturing industry advancements. To remain competitive in the present era and provide the most excellent industry solutions to your organization and target customer group in 2022, you must employ new manufacturing technologies in your manufacturing processes.
Additionally, embracing current technologies is the ideal approach to tackle the industry's current challenges such as workplace safety, digitalization of operations, and a lack of skilled workers.
This article will discuss some of the leading manufacturing technologies that transform traditional manufacturing facilities into smart manufacturing factories. So, let us begin.
Manufacturing Technology & Innovations for 2022
To better understand industry 4.0, let's look at some of the manufacturing technologies that will dominate the manufacturing industry in 2022.
Numerous industries, including aerospace, healthcare, electronics, and architecture, utilize 3D printing in manufacturing. It is the most widely used technology across industries and will remain so in 2022 and in the years to come.
We may also anticipate more advancements in this technology to help overcome current barriers to 3D printing adoption, including equipment costs, material constraints, lengthier manufacturing times, a lack of knowledge, and legal issues.
Additionally, it would assist manufacturers in overcoming current manufacturing challenges such as increasing product demand, increasing automation, and locating and retaining the workforce in manufacturing plants. It is vital to incorporate 3D technology into production processes to achieve greater precision and accuracy in manufacturing.
The Internet of Things is a critical component of the industry 4.0 revolution. It has altered the environment of data collection and analysis across sectors. For example, the Internet of Things is assisting manufacturers in better understanding manufacturing and supply chain operations, forecasting product demand, and boosting customer experiences.
Implementing IoT in your manufacturing plant will also help you avoid production delays and increase the performance of your production lines. Additionally, it will decrease equipment downtime and improve process efficiency. It also enhances worker safety and enables more effective labor management.
To begin implementing IoT in your manufacturing plant, you must first examine your manufacturing processes and research how other organizations have implemented IoT in their manufacturing processes or products. This method will assist you in determining the optimal location to begin integrating the IoT in your manufacturing plants and transforming them into smart ones.
“Once you start to look at yourself in the right way and realize that projects are at the core of your business, it is easy to see how you should use technology to support your business.”
– Matt Mong, VP of Market Innovation and Project Business Evangelist at Adeaca.
GD & T
The model created in the CAD program for any product is not exactly replicated with the exact dimensions during the production procedures. Thus, manufacturers or engineers utilize GD&T (Geometric Dimension &Tolerancing) to manage and communicate the permissible variation within a product assembly to manufacturing partners and inspectors.
GD&T is a programming language that enables developers and inspectors to optimize functionality without incurring additional costs. The primary advantage of GD&T is that it expresses the design intent rather than the final geometry. However, as with a vector or formula, it is a representation of the actual item.
AR & VR
The two primary transformation aspects in the industry 4.0notion are augmented reality (AR) and virtual reality (VR). AR technology in manufacturing enables firms to operate more efficiently by reducing production time. Additionally, it discovers and resolves manufacturing process difficulties.
Virtual reality technology benefits the industrial business in a variety of ways. It enables product designers to mimic their prototypes or models using powerful virtual reality software. This enables them to correct faults at the first stage of production and minimize production time and cost. Additionally, the technology provides additional benefits, such as increased workplace productivity and safety.
Enterprise Resource Planning (ERP) refers to a comprehensive end-to-end software solution that is used across sectors. It assists the manufacturing business in successfully maintaining production processes and other operational data by avoiding numerous roadblocks along the way. ERP technology enables enterprises to improve process efficiency and product quality by tackling industry-specific difficulties such as insufficient data, operation integration, inventory control, supply chain management, and on-time delivery.
Discover How John Deere Manufactured Their Tractors Using Cutting-edge Technologies
John Deere is a significant firm that embraces innovation and the Internet of Things. The company integrates Internet of Things sensors, wireless communication, and intelligent land management systems. It further integrates IoT tools into its manufacturing process, bridging the gap between technologies. Additionally, the company is a pioneer in GPS technology. Its most modern technology, which it incorporates into tractors, is accurate to within two centimeters. Additionally, the organization has implemented telemetry technology for predictive maintenance.
Manufacturing innovations are assisting manufacturers in modernizing their traditional manufacturing processes. Modern manufacturing is equipped with modern technologies that aim to improve the processes and goods, increasing the manufacturers' commercial revenues. So, to remain competitive in this age of technological innovation, manufacturers must update their manufacturing processes to remain relevant in today's manufacturing world.
What is manufacturing innovation?
Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors.
Which technologies are considered to be a component of advanced manufacturing?
3–D printing, robotics, IoT, nanotechnology, cloud computing, robotics, and big data are the significant components of advanced manufacturing.
How are cutting-edge technologies assisting the manufacturing sector?
The cutting-edge technology can precisely estimate demand to set production objectives, analyze machine data to predict when parts will break before a human operator can detect, and more.
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"text": "Manufacturing innovation includes new technology, supply chain modifications, and product and process improvements. As a result, businesses can benefit significantly from innovation and typically surpass their competitors."
"name": "Which technologies are considered to be a component of advanced manufacturing?",
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Article | December 8, 2021
A digital twin is a virtual model of an object or system that comprises its lifecycle. It is updated with real-time data and aids decision-making through simulation, machine learning, and reasoning for the production system.
IoT sensor data from the original object is used to create a digital twin of the system. This cloud-connected data allows engineers to monitor systems and model system dynamics in real-time.
Modifications can be tested on the digital twin before making changes to the original system.
Considering that digital twins are supposed to replicate a product's complete lifecycle and are used throughout the production process, it's not unexpected that digital twins have become prevalent in all stages of manufacturing.
“More than a blueprint or schematic, a digital twin combines a real-time simulation of system dynamics with a set of executive controls,”
– Dr. Daniel Araya, consultant and advisor with a special interest in artificial intelligence, technology policy, and governance
Companies will increasingly embrace digital twins to boost productivity and decrease expenses. As per recent research by Research and Markets, nearly 36% of executives across industries recognize the benefits of digital twinning, with half planning to implement it by 2028.So how does this digital twin technology benefit modern manufacturing? Let's have a look.
How the Digital Twin Drives Smart Manufacturing
Digital twins in manufacturing are used to replicate production systems. Manufacturers can develop virtual representations of real-world products, equipment, processes, or systems using data from sensors connected to machines, tools, and other devices.
In manufacturing, such simulations assist in monitoring and adapting equipment performance in real-time. With machine learning techniques, digital twins can predict future events and anticipate potential difficulties.
For maintenance, digital twins allow for quick detection of any problems. They collect real-time system data, prior failure data, and relevant maintenance data. The technique employs machine learning and artificial intelligence to predict maintenance requirements. Using this data, companies can avoid production downtime.
Digital Twin and Artificial Intelligence (AI) in manufacturing
Using digital twins and AI in production can enhance uptime by predicting potential failures and keeping equipment working smoothly. In addition, there are significant cost savings in the planning and design process as digital twins and AI can be used to replicate a specific scenario.
Maintenance is another area that has seen significant progress with the use of digital twin manufacturing. A Digital Twin powered by AI can predict when a piece of equipment will fail, allowing you to arrange predictive maintenance that is not simply taking information from OEM manuals but can significantly cut maintenance expenses along with reducing downtime.
Using the digital twin, it is feasible to train virtual workers in high-risk functions, similar to how pilots are trained using flight simulators. It also frees up highly skilled workers to upgrade the plant and streamline operations.
General Electric Created the Most Advanced Digital Twin
General Electric Company (GE) is a multinational business based in Boston that was founded in 1892. It has developed the world's most advanced digital twin, which blends analytic models for power plant components that monitor asset health, wear, and performance with KPIs (Key Performance Indicators) determined by the customer and the organization's objectives. The Digital Twin is powered by PredixTM, an industrial platform built to manage huge amounts of data and run analytic algorithms. General Electric Company provides extra "control knobs" or "dimensionality" that can be utilized to improve the operation of the system or asset modeled with GE Digital Twin.
Given the numerous advantages of digital twin manufacturing, the potential for digital twins to be used in manufacturing is virtually endless in the near future. There will be a slew of new advancements in the field of digital twin manufacturing. As a result, digital twins are continually acquiring new skills and capabilities. The ultimate goal of all of these enhancements is to create the insights necessary to improve products and streamline processes in the future.
What is a digital twin in manufacturing?
The digital twins could be used to monitor and enhance a production line or perhaps the whole manufacturing process, from product design to production.
How digital twin benefit manufacturers?
Using digital twins to represent products and manufacturing processes, manufacturers can save assembly, installation, and validation time and costs.
What is a digital thread?
A digital twin is a realistic version of a product or system that replicates a company's equipment, controls, workflows, and systems. The digital thread, on the other hand, records a product's life cycle from creation to dissolution.
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"text": "The digital twins could be used to monitor and enhance a production line or perhaps the whole manufacturing process, from product design to production."
"name": "How digital twin benefit manufacturers?",
"text": "Using digital twins to represent products and manufacturing processes, manufacturers can save assembly, installation, and validation time and costs."
"name": "What is a digital thread?",
"text": "A digital twin is a realistic version of a product or system that replicates a company's equipment, controls, workflows, and systems. The digital thread, on the other hand, records a product's life cycle from creation to dissolution."