Challenges in Industry Management
- Quick response time to customer orders.
- Meeting short and accurate delivery times.
- Handling small quantities with a wide variety of customized products.
- Maintaining reasonable prices while delivering high-quality products with good cost performance.
The trend of smart manufacturing
- Having a significant impact on the industry
(The emergence of mass customization, where small-batch production, inventory management, fast delivery, and diverse product offerings have become the norm. )
- Having a significant impact on the industry
- Productivity has greatly improved, and traditional operational cost advantages are no longer present,
(Resulting in the return of manufacturing to developed countries and increased costs for latecomer firms. )
- Productivity has greatly improved, and traditional operational cost advantages are no longer present,
- The integration of virtual and physical technologies has matured, leading to a comprehensive acceleration of the product lifecycle
(Including product development, sampling, mass production, order delivery, and product recycling. )
- The integration of virtual and physical technologies has matured, leading to a comprehensive acceleration of the product lifecycle
- The full integration of internal and external information has led to a comprehensive upgrade of manufacturing operations
(Including collaborative development, operational information linkage, comprehensive traceability, integrated services, and customized supply.)
- The full integration of internal and external information has led to a comprehensive upgrade of manufacturing operations
Unclear material usage
Gate management: ineffective recycling and inaccurate accounting.
Complex material types: many material types lead to common occurrences of overdraw or material substitution.
Cooperation difficulties
Inaccurate scheduling: There are many factors to consider, and it is difficult to obtain information accurately.
Asynchronous demand: Customer demand is constantly changing.
Production inefficiency
Production capacity is unbalanced: The workload of machines and personnel is uneven.
Lack of transparency in work in progress: The progress of work in progress is not transparent in real-time, with many parameters controlled manually, leading to uncontrolled risks.
Equipment management chaos
Ineffective mold management: There are a large number of molds with frequent changes, making it difficult to keep track of the mold status.
Untimely maintenance: Equipment and molds are not maintained according to the plan, often resulting in machine failures or mold abnormalities, causing downtime or quality issues.
Industry Solutions
1.To maximize production capacity: plan and assign work orders efficiently
Ensure timely supply of materials.
The procurement schedule of non-critical materials can be determined based on the expected start date of production as planned in the production schedule.
Critical materials should be the constraint in scheduling production plans.
Scheduling considerations for the plastic industry:
1. Setup time
2. Batch conditions
3. family mold conditions
Considerations for mold batching in the plastic industry:
1. Change product number while using the same mold and same color.
2. Same mold but different color
3. Mold change
2.Production line transparency: The production process can be controlled.
During production in the plastics industry, integration of human-machine interface equipment
During production in the plastics industry,is used to monitor production activities and provide automatic production feedback through electronic display boards. This includes feedback on
1. mold cycles
2. mold changes
3. changes in mold cavities
4. considerations of cavity numbers
5. considerations of family molds
3.Real-time inspection: Quality check – Ensuring product quality
- The right person should look at the right report
- Multiple appropriate reports monitored in real-time by one person – visualization
- Control only anomalies and warnings, which can be dealt with immediately.
- Prevention beforehand
- Real-time monitoring during
- Rapid analysis afterwards
Implementation Benefits
