Article | May 10, 2021
Jason Spera, picture left, recently shared his vantage of the changes for factory floor automation in 2021. Jason is CEO and Co-Founder, Aegis Software. Spera is a leader in MES/MOM software platforms for discrete manufacturers with particular expertise in electronics manufacturing. Founded in 1997, today more than 2,200 factory sites worldwide use some form of Aegis software to improve productivity and quality while meeting regulatory, compliance and traceability challenges. Spera's background as a manufacturing engineer in an electronics manufacturing company and the needs he saw in that role led to the creation of the original software products and continue to inform the vision that drives Aegis solutions, like FactoryLogix. He regularly speaks on topics surrounding factory digitization, IIoT, and Industry 4.0. Contact Jason on LinkedIn.
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 | December 13, 2021
Lean manufacturing principles enable manufacturing businesses to achieve spectacular results and overhaul their conventional operations. A wide range of industries have adopted lean manufacturing because of its enormous advantages, and they have seen excellent results as a result.
The 2010 Compensation Data Manufacturing survey indicated that 69.7% of manufacturing organizations employ lean manufacturing principles. By consuming this data, we can understand how far organizations have progressed toward incorporating lean principles into their operations.
“Many companies are not willing to change or think they are done once they make a change. But the truth is technology, consumer demands; the way we work, human needs, and much more are constantly changing.”
–Michael Walton, Director, Manufacturing Industry Executive at Microsoft
Let's look at some examples of lean manufacturing from some well-known companies. These leading-edge examples of lean manufacturing will shed light on how lean principles positively affect.
Leading Companies Using Lean Manufacturing Effectively
Successful manufacturing businesses like Toyota, Nike, and Caterpillar are currently employing lean manufacturing ideas in their production processes. In addition, Intel, Parker Hannifin, and John Deere embrace these techniques. From them, we've described three different organizations in various sectors that are successfully adopting lean manufacturing.
John Deere has also implemented a lean manufacturing strategy. As a result, many of their quality control procedures are automated, which means that more components can be checked for flaws in less time. This means that more supply can be released each day, and the product can be supplied at a lower price to the consumer.
Additionally, these controls monitor the manufacturing process for each component of their products, ensuring that they never manufacture more than is required and waste essential materials in the process.
Intel, known for its computer processors, has used lean manufacturing techniques to provide a higher quality product for an industry that requires zero defects. In the past, it took more than three months to get a microprocessor to the manufacturer, but this principle has helped shorten that time to less than ten days.
Intel rapidly learned that creating more but worse quality was not the way to raise revenues and increase consumer satisfaction with its products, which were extremely precise and technical. Instead, both parties gain from quality control and waste reduction initiatives. This is even true in the tech industry, where goods are constantly changed and upgraded.
Toyota, the world's largest automaker, was the first to implement lean manufacturing in its manufacturing operations. But, even more importantly, they've learned how to limit products that don't match customer expectations by eliminating waste. To achieve these goals, Toyota employs two essential procedures.
The first is a method known as Jidoka, which loosely translates as "automation with the assistance of humans." This implies that, although some of the work is automated, humans always ensure that the result is of the highest quality.
When something goes wrong, the machines have built-in programs that allow them to shut themselves down. Known as the Just In Time (JIT) model, this is the second stage. Once the last part of a process has been finished, the next phase can begin. No unnecessary work will be done if there is a problem with the assembly line. This lean manufacturing technique has inspired thousands of other businesses.
Lean manufacturing principles and their execution require discipline and patience to get the results out of them. When we see the successful lean manufacturing examples, it is not a fraction of a second success. They have devoted their time, energy, and efforts to modifying every single operational process in order to become a part of lean manufacturing. Lean manufacturing is not a method; it is a way of life that transforms your business practices and takes your firm to a new level of operations. Gain insights from renowned organizations' lean manufacturing success stories to help you become a part of the lean companies of 2022.
What is the effect of lean manufacturing?
Lean is a performance-based, continuous-improvement strategy that removes waste and unnecessary processes from organizational operations. As a result, your company becomes more focused on the results.
Is it possible for lean manufacturing to fail?
It is conceivable in some circumstances, such as failing to focus on a single system implementation or implementing too many system changes at once and failing to have a sound follow-up system to check that everything is working effectively.
Why do certain businesses struggle with lean manufacturing?
Most businesses fail to see that lean is a management philosophy, not a set of tools. As a result, most corporate leaders either don't understand or lack the patience and control to implement lean manufacturing.
"name": "What is the effect of lean manufacturing?",
"text": "Lean is a performance-based, continuous-improvement strategy that removes waste and unnecessary processes from organizational operations. As a result, your company becomes more focused on the results."
"name": "Is it possible for lean manufacturing to fail?",
"text": "It is conceivable in some circumstances, such as failing to focus on a single system implementation or implementing too many system changes at once and failing to have a sound follow-up system to check that everything is working effectively."
"name": "Why do certain businesses struggle with lean manufacturing?",
"text": "Most businesses fail to see that lean is a management philosophy, not a set of tools. As a result, most corporate leaders either don't understand or lack the patience and control to implement lean manufacturing."
Article | October 13, 2021
The electronics manufacturing business is adopting new technologies to create smart electronics manufacturing products for its consumer base. Next-generation technologies are shaping the future of the manufacturing industry by enabling it to create technologically advanced and user-friendly products. Matt Mong, one of the manufacturing industry's leading professionals, stated in an interview with Media7,
“Be Different. Don’t position your product in an existing category. Instead, create your category and make the competition irrelevant and obsolete.” – Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca.
The year 2022 will be a year of advancement and development for the electronics manufacturing industry.
So, manufacturers are eager to embrace new technologies and produce more innovative, more user-friendly goods that become part of consumers' daily lives and meet their needs. To make the manufacturing process manageable and deliver advanced products, we will look at the top five trends flourishing in the electronics manufacturing industry.
Top Five Electronics Manufacturing Industry Trends
Future manufacturing technologies are transforming the electronics manufacturing industry's processes and products. Let's look at the top electronics manufacturing industry trends for 2022, which will propel the sector to new heights of technological advancement.
Utilizing the Benefits of the Internet of Things
The Internet of Things is being used in both the manufacturing process and the products themselves. It enables electronic manufacturing products and processes to become more intelligent and performance-driven to fulfill business and customer needs.
In electronics manufacturing, the Internet of Things (IoT) enables businesses to solve common production challenges such as product quality issues, changing demands, and a complex global supply chain. As a result, it increases productivity and efficiency while reducing human effort.
Industrial units may gather and analyze real-time data and processes using IoT-based sensor systems. Additionally, it assists organizations in managing data and transforms traditional manufacturing into an intelligent manufacturing unit.
Using an ERP System to Maintain the Company's Competitive Edge
ERP (Enterprise Resource Planning) is a centralized management system for all operational and business activities. The software automates all manufacturing processes and enables the electronics manufacturing sector to achieve higher precision throughout the manufacturing process and product delivery.
ERP has the potential to boost productivity, improve efficiency, decrease expenses, and increase profitability. ERP enables electronics manufacturers to forecast, plan, modify, and respond to changing market demands. By using an ERP system in your manufacturing unit, you may expand your business and increase revenue.
Making Use of Big Data
The electronics manufacturing industry benefits from the use of big data to make critical business decisions. It aids in the integration of previously isolated systems to provide a comprehensive view of industrial processes. It also automates data gathering and processing, allowing for more excellent knowledge of each system individually and collectively.
Big data also assists manufacturers in discovering new information and identifying trends, allowing them to optimize operations, improve supply chain efficiency, and find variables that impact manufacturing quality, volume, or consistency. In addition, big data assists the electronics manufacturing industry in keeping up with the rapidly changing digital world.
Using AR and VR to Create Consumer-friendly Goods
AR and VR are future manufacturing technologies that are changing electronics manufacturing products and driving growth. Robotics is a crucial usage of virtual reality in electronics production. Manufacturers may use powerful virtual reality software to design goods. This implementation of virtual reality software reduces production errors and saves time and money.
AR in electronics manufacturing allows product developers to generate interactive 3D views of new products before production. AR and VR are part of Industry 4.0, the digital revolution of conventional electronics production units.
Adoption of 3D Printing on a Wide Scale
One of the essential advantages of today's electronics 3D printing is that companies can quickly prototype PCBs and other electrical devices in-house. In addition, 3D printing has simplified the electronics manufacturing process, and it is currently being utilized to manufacture multilayer printed circuit boards. It uses material jetting technology to spray conductive and insulating inks onto the printing surface.
Let's look at an example of an analogy that worked for Jinzhenyuan - The Electronic Technology Co. Ltd., managed by Mr. Huang Runyuan, Jinzhenyuan's General Manager, and based on the concept of Industry 4.0. (Reference: Forbes)
Jinzhenyuan - The Electronic Technology Co. Ltd. Takes a Significant Step Forward with Industry 4.0
Jinzhenyuan - The Electronic Technology Co. Ltd., formed in 2012, sells its products globally. In addition, it manufactures cellphones, computers, cars, and a variety of other consumer electronics. Due to changing market needs, the firm planned to upgrade its production facility to industry 4.0 by the end of 2017 to participate in smart manufacturing.
The company increased production efficiency, shortened production cycles, and cut costs due to the digital revolution. Today, Jinzhenyuan is regarded as a model of digital transformation in the community in which it works. Let’s observe the statistics for Jinzhenyuan following the deployment of Industry 4.0.
32% improvement in total production efficiency
33% cost reduction
41% decrease in R&D to production cycles
51% reduction in substandard parts rate – from 3,000 to 1,500 per million
The electronics manufacturing sector is on the verge of a digital revolution that will improve the production process efficiency and cost-effectiveness. Many of the world's biggest firms, like Apple, Microsoft, Hitachi, and Saline lectronics, are developing future agile factories to keep up with the world's digital transformation. Future manufacturing technology will help your manufacturing company make the manufacturing process more efficient and boost the business revenue.
What are the future electronics technologies?
Smart grid solutions, wearable technology devices, prefabricated goods, the Internet of Things, and robots are some of the future electronics innovations that will propel the business forward.
Is the supply chain benefiting from new technology trends?
Yes, supply chain management benefits from smart technology as well. Trucks equipped with cutting-edge technologies can get real-time data on the weather and road conditions ahead of time. It contributes to the supply chain process's reduction of possible risks.
Which manufacturers are implementing the industry 4.0 concept in their factories?
Whirlpool, Siemens, Hirotec, Tesla, Bosch, and Ocado, among others, have turned their traditional factories into digitally smart ones that incorporate all of the cutting-edge technology necessary to improve and optimize the production process.
"name": "What are the future electronics technologies?",
"text": "Smart grid solutions, wearable technology devices, prefabricated goods, the Internet of Things, and robots are some of the future electronics innovations that will propel the business forward."
"name": "Is the supply chain benefiting from new technology trends?",
"text": "Yes, supply chain management benefits from smart technology as well. Trucks equipped with cutting-edge technologies can get real-time data on the weather and road conditions ahead of time. It contributes to the supply chain process's reduction of possible risks."
"name": "Which manufacturers are implementing the industry 4.0 concept in their factories?",
"text": "Whirlpool, Siemens, Hirotec, Tesla, Bosch, and Ocado, among others, have turned their traditional factories into digitally smart ones that incorporate all of the cutting-edge technology necessary to improve and optimize the production process."