The cost of manufacturing is a complex equation that integrates the labor burdened rate and inventory burdened rate. For every dollar spent on wages, an additional twenty-five cents or 25% is incurred as the burdened cost. This figure reflects the comprehensive expenses of employing workers, encompassing not only their wages but also benefits, taxes, and other related costs.
The Hidden Costs of Unproductive Time
Every minute of unproductive time during scheduled shifts accumulates costs, representing wasted resources and lost potential. Idle time can result from various factors such as machine breakdowns, lack of materials, or inefficient workflows. This unproductive time directly impacts the bottom line, inflating operational expenses without contributing to output.
The Dangers of Excessive WIP Inventory
Unsold inventory is unrealized revenue, but Work In Progress (WIP) inventory is particularly detrimental. Extensive WIP ties up capital and incurs ongoing expenses. When items linger in various production stages without progressing to finished goods, it indicates inefficiencies that slow down the overall workflow. This bottleneck leads to delays and resource wastage, further exacerbating the cost problem.
The Need for a Paradigm Shift
Manufacturers must recognize that incremental improvements can lead to substantial gains in sellable goods, delivery times, and overall cost reduction. This requires a shift from traditional cost accounting to throughput accounting. Throughput accounting focuses on maximizing the rate at which the system generates money through sales, thus highlighting the importance of efficient production processes.
Championing Efficiency and Innovation
Management must consciously embrace this paradigm shift and assign a champion to identify and correct micro stoppages and process inefficiencies. By evaluating value streams and correcting unbalanced allocations, manufacturers can streamline operations and enhance productivity. Engaging operators and educating them on efficient processes, tools, and regimens is crucial for sustaining these improvements.
Learning from the Leaders
Over the past 70 years, continuous improvement strategies have been championed by global manufacturing leaders like Toyota. However, many North American manufacturers chose to outsource operations overseas, seeking lower labor costs. Now, the trend of reshoring manufacturing back to America underscores the critical importance of being lean and efficient.
The Promise of Smart Systems
Modern smart systems like MERLIN offer a platform to integrate traditional ERP, MES, QC, and maintenance systems. These flexible and adaptable systems can respond to changing conditions, capturing and identifying complex scenarios for corrective action. Unlike simple monitoring systems that can lead to inflexible and limited improvements, smart systems provide actionable information for comprehensive and sustainable advancements.
Addressing the Skills Gap
Manufacturers often face challenges in finding skilled personnel and engineers. Forward-thinking companies are engaging continuous improvement engineering firms on short-term contracts to help select and marshal internal resource teams. These teams address issues and implement changes, resulting in rapid and long-lasting payback through demonstrated new strategies based on accurate, actionable information from smart systems.
The Future of American Manufacturing
Over the next decade, we will witness a transformation as old, inefficient companies are replaced by lean, efficient, and profitable manufacturers. The era of outsourcing production is drawing to a close. The future of American manufacturing hinges on today’s executive management, who must empower their teams and embrace technological advancements.
These executives, familiar with technology from their upbringing, can no longer cite lack of adoption due to resistance to change. The new management must embrace the spirit of the industrial revolution, driving their companies toward innovation and efficiency. Playing it safe will only result in being left behind, trailing in the competitive landscape.
In conclusion, the path to revitalizing American manufacturing lies in committing to revolutionary change, leveraging smart systems, and fostering a culture of continuous improvement. By doing so, US companies can reclaim their position as global leaders in manufacturing, driving economic growth and industrial prowess into the future.
References
– Womack, J.P., Jones, D.T., & Roos, D. (1990). *The Machine That Changed the World: The Story of Lean Production*. Harper Perennial.
– Liker, J.K. (2004). *The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer*. McGraw-Hill.
– Goldratt, E.M., & Cox, J. (1984). *The Goal: A Process of Ongoing Improvement*. North River Press.
by
Tim Smith
Addressing Industry 4.0 Concerns with MERLIN Tempus EE
/in Articles, Blog, Recent NewsImplementing Industry 4.0 solutions like MERLIN Tempus Enterprise Edition (EE) can raise concerns among production and plant managers. By leveraging insights from recent MEMEX articles and highlighting the platform’s core features, this response demonstrates how MERLIN Tempus EE effectively addresses these concerns while driving cultural transformation, operational efficiency, and innovation.
Shop Floor Adoption of Technology
Message:
“We understand the challenge of introducing new technology to the shop floor. The uncertainty of acceptance can stymie any technology deployment. Advanced machine tools and robotics introduce more of a disruptive influence than MERLIN ever will. MERLIN Tempus EE simplifies adoption with its intuitive design, user-friendly interface, and seamless integration into existing workflows. We provide robust training and support to ensure smooth implementation and confident usage.”
Supporting Information:
Accuracy of Data
Message:
There is a host of systems developed internally or offered by various software vendors that can’t deliver on anything more than the simplest of data connections. The fact is, connecting to the machine should no longer be the hard part. “Accurate data is at the core of MERLIN Tempus EE. By directly connecting to machines and automating data capture, the platform ensures reliability and eliminates errors associated with manual entry.” MERLIN eliminates double-entry and minimizes operator input to only essential responses.
Supporting Information:
Data Utilization (Avoiding Unused Data Lakes)
Message:
“MERLIN Tempus EE transforms raw data into actionable insights. By aligning data collection with your KPIs, the system ensures every data point contributes to operational improvements.” MERLIN has twenty plus metrics being calculated.
Supporting Information:
Project Cost Overruns and Predictability
Message:
“We understand that cost control is a top priority. MERLIN Tempus EE offers modular, scalable deployment options that allow you to start small, prove ROI, and scale up based on your budget and requirements.”
Supporting Information:
Risk of Project Failure
Message:
“Our implementation methodology ensures clear milestones, frequent reviews, and collaborative engagement to mitigate risks and ensure project success.”
Supporting Information:
Past Negative Experiences (e.g., ERP/MES Deployments)
Message:
“We understand that past deployments may have fallen short. MERLIN Tempus EE differentiates itself by focusing on simplicity, fast integration, and empowering teams with actionable data to enhance decision-making.”
Supporting Information:
Stakeholder Buy-In Challenges
Message:
“MERLIN Tempus EE ensures cross-departmental buy-in by aligning its benefits with the priorities of operations, finance, and management. Real-time data fosters collaboration and demonstrates measurable ROI for all stakeholders.”
Supporting Information:
Closing Assurance
“By choosing MERLIN Tempus EE, you’re investing in a proven solution designed to address your operational challenges while driving cultural transformation. With features tailored for efficiency, accuracy, and collaboration, MERLIN ensures a seamless transition to enhanced manufacturing operations.”
Effective Shop Floor Management: Key Issues and Solutions
/in Articles, Blog✨ Managing a shop floor effectively requires a focus on real-time visibility, operational efficiency, and product quality. These goals hinge on addressing critical performance metrics: production progress, machine utilization, and quality indicators. This article explores these metrics, the factors influencing them, and strategies to identify and address root causes for continuous improvement. ✨
Key Performance Metrics on the Shop Floor
1. Production Progress
⚡ Production progress measures how effectively manufacturing schedules are adhered to. Influencing factors include: ⚡
2. Machine Utilization
⚙ Machine utilization reflects the effective use of equipment during production. Key factors are: ⚙
3. Quality Indicators
🔧 Quality indicators assess adherence to product specifications and standards. Major influences include: 🔧
Grouping Root Causes for Resource Focus
🔄 To tackle these issues efficiently, contributing factors can be grouped into broader categories for targeted resource allocation: 🔄
1. Workforce and Skills
2. Equipment and Maintenance
3. Process Management
4. Material and Supply Chain
🌏 – Factors Included: Material availability, material quality.
5. Quality Assurance
❤️ – Factors Included: Inspection, environment, root cause analysis.
Prioritizing Critical Areas
✨ Among all categories, Equipment and Maintenance often take precedence. Equipment reliability directly impacts production flow, product quality, and workforce efficiency. By prioritizing improvements here, cascading benefits are realized across other metrics. ✨
Strategies for Continuous Improvement
☘ Effective strategies for addressing root causes include: ☘
Conclusion
🙌 Effective shop floor management depends on identifying and addressing the root causes of performance issues. By grouping factors into key areas—workforce, equipment, processes, materials, and quality—organizations can focus resources where they are most impactful. A strategic approach fosters efficiency, improves quality, and drives sustainable growth. 🙌
To support this process, robust data collection and analysis tools like MERLIN Tempus Enterprise Edition enable informed decision-making and rapid response to inefficiencies. Learn more at www.memexoee.com.
An approach to Cultural Change on the Shop Floor
/in Articles, BlogThe topic is quite extensive, so, for this short article I will touch on an approach to and a high level action plan to effect successful cultural change.
Explanation and Action Steps
Explanation:
When attempting to initiate organizational change, it’s essential to recognize that both technical and psychological components are involved. The first two questions, What to Change? and What to Change Into? are primarily technical; they focus on identifying the specific issue that needs to be addressed and the desired outcome. These are the practical, data-driven questions that drive the problem-solving process. However, the third question, How to Cause the Change? is fundamentally psychological, as it involves managing emotional resistance within the organization.
Politics and established ways of doing things in many organizations create a natural resistance to change. The emotional pushback is a key obstacle, as individuals often perceive change as threatening their security. This perception can stem from fear of the unknown, fear of failure, or fear of losing control. As such, change is often met with emotional resistance, which, if not managed carefully, can derail even the best-planned initiatives. Understanding this psychological process is crucial to successfully navigating the change process and ensuring that the organization continues to improve sustainably.
Emotional Resistance to Change:
The challenge here is to find a way to create a productive emotional response to change that outweighs the natural resistance. Traditional methods such as using fear or insecurity (e.g., “change or else we will fall behind”) may work initially but are not sustainable in the long term. They often create an environment of constant tension and insecurity, which leads to burnout, disengagement, and eventually stagnation.
The Power of the Emotion of the Inventor:
Rather than using fear or insecurity, a more positive and sustainable approach involves tapping into the emotion of the inventor—the powerful feeling of ownership and personal connection to a solution. This emotion arises when individuals come up with their own solutions to problems, as opposed to simply being told what to do.
The Socratic method, which encourages individuals to find their own answers by asking the right questions, can be an effective tool in inducing this emotion. It not only helps individuals feel ownership over the solution, but it also engages their creativity and problem-solving skills, leading to deeper commitment to the change process.
Action Steps:
Following these steps can create a more sustainable and positive change process. The key is to focus on emotional engagement, foster ownership, and avoid relying on fear or insecurity. This approach will help you implement successful changes and ensure that your organization remains adaptable, resilient, and continuously improving over time.
by Tim Smith
The Current State of Manufacturing in the USA
/in Articles, Blog, Recent NewsManufacturing in the United States is at a pivotal juncture. Over the past decade, efforts to bolster domestic manufacturing have intensified due to geopolitical shifts, trade imbalances, and the economic repercussions of over-reliance on global supply chains. Key drivers of this renewed focus include the strategic application of tariffs, incentives to re-shore production, and a national commitment to revitalizing the manufacturing sector. This approach aims to mitigate vulnerabilities exposed during global disruptions while creating jobs and fostering economic growth.
Despite these efforts, the global manufacturing landscape remains highly competitive. U.S. manufacturers face significant challenges, including higher labor costs, stringent regulatory requirements, and the increasing demand for customization and rapid delivery. To address these issues and remain competitive, the industry is adopting cutting-edge technologies to maximize efficiency, reduce waste, and enhance visibility into manufacturing processes.
Focus on Smart Manufacturing and Efficiency
Efficiency has become the cornerstone of modern manufacturing. Smart manufacturing technologies empower companies to optimize processes, reduce downtime, and increase productivity. Central to this transformation is the implementation of advanced tools like MERLIN Tempus Enterprise Edition (EE) , which brings a new level of visibility, connectivity, and performance tracking to the factory floor.
MERLIN Tempus EE offers a robust solution for integrating manufacturing operations management with Enterprise Resource Planning (ERP) systems, enabling seamless data exchange and actionable insights. With these tools, manufacturers can effectively compete by leveraging real-time data to make informed decisions, meet customer demands, and reduce overhead costs.
The Role of MERLIN Tempus EE in Modern Manufacturing
ERP Integration and Transparency
MERLIN Tempus EE extends traditional ERP systems by feeding them real-time data from the shop floor. For example, if a customer inquires about the status of an order, MERLIN provides instant visibility into where the work order is in the production process, eliminating the need for manual inquiries and delays. This connectivity allows manufacturers to meet deadlines with greater accuracy and foster trust with customers.
Enhanced Features
The MERLIN Tempus EE software is designed to enhance efficiency and productivity through a comprehensive set of features:
– Dynamic Job Scheduling: Allows real-time adjustments to operation steps and prioritization of tasks.
– Performance Tracking: Measures jobs against product standards, providing insights into labor and machine performance.
– Labor and Machine Management: Tracks multiple operators and machines, optimizing resource allocation.
– Data Exchange: Facilitates integration with other applications, supporting APIs and JSON for dynamic connectivity.
Driving Continuous Improvement
MERLIN Tempus EE supports lean initiatives by uncovering hidden production capacity, identifying constraints, and validating process improvements. It enables manufacturers to:
– Reduce downtime.
– Identify operational bottlenecks and inefficiencies.
– Improve overall equipment effectiveness (OEE).
– Foster a culture of collaboration and data-driven decision-making.
Modular Design for Future Readiness
The modular architecture of MERLIN Tempus EE ensures compatibility with emerging technologies, empowering factories to integrate future advancements in smart manufacturing. This adaptability is crucial as the industry evolves toward greater automation, predictive analytics, and machine learning.
The Path Forward for U.S. Manufacturing
U.S. manufacturers must embrace smart technologies like MERLIN Tempus EE to remain competitive. These tools provide a pathway to achieving world-class efficiency and meeting the demands of modern manufacturing. By integrating advanced software solutions with strategic initiatives, manufacturers can bring production back to the U.S. while maintaining the cost-effectiveness needed to thrive in a global marketplace.
Investments in technology, workforce training, and process optimization will ensure that U.S. manufacturing remains a cornerstone of economic growth and innovation. MERLIN Tempus EE exemplifies how digital transformation can drive the industry toward a more sustainable and prosperous future.
by: Tim Smith, Director of Technology Adoption
Revolutionizing Manufacturing: Embracing Efficiency and Innovation
/in Articles, BlogThe cost of manufacturing is a complex equation that integrates the labor burdened rate and inventory burdened rate. For every dollar spent on wages, an additional twenty-five cents or 25% is incurred as the burdened cost. This figure reflects the comprehensive expenses of employing workers, encompassing not only their wages but also benefits, taxes, and other related costs.
The Hidden Costs of Unproductive Time
Every minute of unproductive time during scheduled shifts accumulates costs, representing wasted resources and lost potential. Idle time can result from various factors such as machine breakdowns, lack of materials, or inefficient workflows. This unproductive time directly impacts the bottom line, inflating operational expenses without contributing to output.
The Dangers of Excessive WIP Inventory
Unsold inventory is unrealized revenue, but Work In Progress (WIP) inventory is particularly detrimental. Extensive WIP ties up capital and incurs ongoing expenses. When items linger in various production stages without progressing to finished goods, it indicates inefficiencies that slow down the overall workflow. This bottleneck leads to delays and resource wastage, further exacerbating the cost problem.
The Need for a Paradigm Shift
Manufacturers must recognize that incremental improvements can lead to substantial gains in sellable goods, delivery times, and overall cost reduction. This requires a shift from traditional cost accounting to throughput accounting. Throughput accounting focuses on maximizing the rate at which the system generates money through sales, thus highlighting the importance of efficient production processes.
Championing Efficiency and Innovation
Management must consciously embrace this paradigm shift and assign a champion to identify and correct micro stoppages and process inefficiencies. By evaluating value streams and correcting unbalanced allocations, manufacturers can streamline operations and enhance productivity. Engaging operators and educating them on efficient processes, tools, and regimens is crucial for sustaining these improvements.
Learning from the Leaders
Over the past 70 years, continuous improvement strategies have been championed by global manufacturing leaders like Toyota. However, many North American manufacturers chose to outsource operations overseas, seeking lower labor costs. Now, the trend of reshoring manufacturing back to America underscores the critical importance of being lean and efficient.
The Promise of Smart Systems
Modern smart systems like MERLIN offer a platform to integrate traditional ERP, MES, QC, and maintenance systems. These flexible and adaptable systems can respond to changing conditions, capturing and identifying complex scenarios for corrective action. Unlike simple monitoring systems that can lead to inflexible and limited improvements, smart systems provide actionable information for comprehensive and sustainable advancements.
Addressing the Skills Gap
Manufacturers often face challenges in finding skilled personnel and engineers. Forward-thinking companies are engaging continuous improvement engineering firms on short-term contracts to help select and marshal internal resource teams. These teams address issues and implement changes, resulting in rapid and long-lasting payback through demonstrated new strategies based on accurate, actionable information from smart systems.
The Future of American Manufacturing
Over the next decade, we will witness a transformation as old, inefficient companies are replaced by lean, efficient, and profitable manufacturers. The era of outsourcing production is drawing to a close. The future of American manufacturing hinges on today’s executive management, who must empower their teams and embrace technological advancements.
These executives, familiar with technology from their upbringing, can no longer cite lack of adoption due to resistance to change. The new management must embrace the spirit of the industrial revolution, driving their companies toward innovation and efficiency. Playing it safe will only result in being left behind, trailing in the competitive landscape.
In conclusion, the path to revitalizing American manufacturing lies in committing to revolutionary change, leveraging smart systems, and fostering a culture of continuous improvement. By doing so, US companies can reclaim their position as global leaders in manufacturing, driving economic growth and industrial prowess into the future.
References
– Womack, J.P., Jones, D.T., & Roos, D. (1990). *The Machine That Changed the World: The Story of Lean Production*. Harper Perennial.
– Liker, J.K. (2004). *The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer*. McGraw-Hill.
– Goldratt, E.M., & Cox, J. (1984). *The Goal: A Process of Ongoing Improvement*. North River Press.
by
Tim Smith