Challenges in Industry Management
- Forecasting for rough (casting/forged) products are often done manually and based on experience, resulting in either overstocking, increasing inventory cost, or underestimating, leading to delayed delivery times.
- In order to plan and schedule orders, it is necessary to consider not only the available rough products but also to have real-time access to materials, work-in-progress, and production capacity to determine if delivery times can be met.
- The manufacturing process is complicated, and despite allowing for buffer times, actual production time is low due to stoppages and downtime, making it difficult to shorten the production cycle.
- It is difficult to control the assembly and packaging process as the production progress cannot always follow a predetermined plan, and ensuring that all parts are available for packaging is challenging.
Unable to manage the supply chain of raw materials and production schedules
Collaboration between upstream and downstream partners is common in the casting industry, with the main processes being the in-house precision casting and outsourced CNC machining, heat treatment, and surface treatment. However, the lack of digitization and reliance on manual operations makes it difficult to monitor cross-chain support, production schedules (such as processes, quantities, and delivery dates), quality information, and other aspects. As a result, the supply chain delivery accuracy is only around 70% (far lower than the automotive industry’s delivery accuracy of 100%).
Information acquisition is based on lagging indicators and lacks a comprehensive resume
The information obtained in the 3K traditional industry is still based on outdated indicators and lacks complete traceability. The process of intelligentization in this industry is slow, and manual paper-based operations are still common. This belongs to the “back-end” of smart manufacturing, where the information is not timely, not accurate, and lacks completeness, making it difficult to respond quickly to the endless changes in the manufacturing process. It is also difficult to meet the flexible production needs of small batches and multiple varieties.
Inspection for small batches and various products is difficult and relies on manual labor
Quality and yield have always been a concern in manufacturing. For casting products, quality inspection can only be conducted at the final process station or after a certain manufacturing process. However, manual inspection standards are difficult to unify, resulting in an average inspection rate of only 75%. This makes quality control difficult and accuracy and yield difficult to improve, thus making it difficult to enter high-quality markets.
Industry Solutions
Knowledge
Demand management, capacity assessment, lead time.
Mechanisms
Production pacing mechanism Material tracking and expediting mechanism Scheduling and dispatching mechanism Production progress tracking mechanism Equipment management mechanism
Processes
Demand forecasting and clearance process Standard working hours definition process Production dispatching process Production progress reporting process Production progress tracking and expediting process Equipment status change process Equipment integration abnormal handling process.
Tools
MDS offset maintenance operation Materials follow-up and expediting table sMES basic setup planning Product standard labor and production resource cycle time sMES dispatching sMES progress reporting planning sMES machine status and utilization planning.
Indicators in production management
Work order completeness rate Work order on-time start rate Expected order delivery date Production delivery lead time Dispatch completion rate
Monitoring
Purchase order overdue alert, order/work order shortage alert, order delay days, internal bottleneck load alert, dispatch plan achievement report.
行業解決方案
知識
需求管理，產能評估， 週期時間
機制
生產節拍，物料跟催機制，排程派工機制，生產進度追蹤機制，設備管控機制
流程
需求預測沖銷流程，標準工時定義流程，產派工流程，生產進度回報流程，生產進度跟催流程，機台狀態變更流程，機台整合異常處理流程。
工具
MDS沖銷維護作業，物料跟催表，sMES基本設定規劃，產品標工、生產資源週期時間，sMES派工，sMES進度報工規劃，sMES機台狀態和稼動規劃。
指標
工單齊套數，工單準時開工率，訂單預計達交日，生產交付天數，派工達成率。
監控
採購單逾期警示，訂單\工單欠料警示，訂單延遲天數，廠內瓶頸負荷警示，派工計畫達成表。
Industry Solutions
Return on Investment (ROI)
By implementing the solution, the accuracy of material planning can be improved, resulting in a 15% reduction in material inventory. In addition, the efficiency of the manufacturing process can be improved, resulting in labor cost savings due to an expected 18% increase in yield and a reduction in manual welding, rework, and polishing.
Overall Equipment Effectiveness (OEE)
Can reduce secondary rates and reduce the defect occurrence rate by 10%. The utilization rate is increased to 90%, the production efficiency is maintained at 85%, and the yield rate is increased to 80%, resulting in a 9% increase in OEE.
Shortening Lead Time
The collection of cross-factory production progress and quality information will be improved from manual operation to digital streaming. It is expected that the lead time can be shortened by 20%.
Industry Solutions
