In a previous article (Data That Doesn’t Lead To Action Is Useless!), we outlined how we discovered the limitations of raw data and why we turned to a communication model to grow our business. In this article, we will outline the precise steps we took to implement the process platform that transformed our company from just another job shop to an industry leader.

A Platform for Manageable Action
We began the process by creating an internally designed information platform constructed around our basic set of business rules. To give you an idea of the magnitude of this task and our commitment, it took two years just to develop all the factors of the manufacturing process in the critical window (from ordering materials to shipment date). The platform had to capture data on all 26 variables, interpret it and deploy it to the employees on the floor to execute. The flow had to be seamless and repeatable to avoid any opportunity for misinterpretation.

For every part we manufacture, we now generate an Electronic Demand Profile (EDP) through our electronic resource planning (ERP) software. The ERP includes a system of integrated applications to manage the manufacturing process. In other words, we can capture all the data about the specific part plus all the operations (laser cutting, forming, welding, etc.), materials and actions needed to fabricate the piece. Anything anyone needs to know about the job is right there. From sales to purchasing to the individual machines, each employee has a dashboard that shows the actions they must take to complete the job. An EDP is also created for every new part or new variations of an existing part.

The Platform in Action
Information on each ongoing job is monitored daily and any exceptions (information that changed from the day before) is flagged so potential delays can be spotted in advance. This allows us to be proactive and switch jobs to meet the schedule or call the customer and collaborate with them to work out compromises such as extending delivery, etc. Without the dashboards and monitoring, any disruption to the schedule would remain invisible. A production part can take up to four weeks to make, so if we miss a day or two, we won’t make the shipment!

Monitoring the platform also allows us to keep ahead of order fluctuations. We can ramp up personnel requirements and make adjustments in capacity for spikes in demand. Another advantage of the platform is that individual performance is enhanced since each dashboard is customized so each employee sees what they need and only what they need. This eliminates information overload. In many ways, it’s the people who make the platform more of an ecosystem than just another layer of software. Process disciplines are hardwired into our company culture to the point where they are instinctive. Procedures are done the same way every time. It’s this personal element that helps make the platform so successful.

Results
Incorporating a scalable and repeatable information action platform has really allowed us to take the company to new levels. A lot of companies can download the same data that we do, but don’t have the infrastructure in place to interpret it and get it down onto the floor. We can receive up to 4,000 order changes a day. Unless you have the platform to turn “big data” into actionable information, you’re not giving yourself the best chance to succeed.

Let us know how we can put our data management best practices to work for your metal working needs. Contact us today.