Options for tracking production progress

[boltwasher]

I am working on optimizing the production process of a small electronic appliance factory. Production team consists of 7 people.

One of the problems is that at the moment we do not have an effective way of tracking production time and amounts of different assemblies, subassemblies and parts.

Currently we are using MRPeasy, which has a possibility to track these things but for it to work properly and efficiently, a license must be bought for every worker and that is an investment the company is not willing to make at the moment.

Is there a possible software solution that does not require a separate license for every worker and can be accessed through a smartphone?

 

[Brijesh Hirani]

Hello,

Google sheets is an easy option. You can create spreadsheets to record production time and quantities of different components. Operators can access and update the sheets using the Google Sheets app on their phones too.

 

[EdStainless]

How many steps are you tracking and how fast do they happen?
If you have lots of steps and they happen fast then fully integrated solution is likely the only option, costly or not.
If it is not that many steps and they happen over many days then a manual system should work fine.
Anything from Google sheets to a paper-based system to track the time taken and completion of each step.
One place that I worked repurposed old timeclocks.
We printed cards with each step.
You punched in at start and punched out at end of each operation.
Mfg control had someone that came in 2hr early in the morning to read all cards and update the schedule.
It gave us tracking of both flow and time at each operation (and between operations).
It was just clunky.

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P.E. Metallurgy, consulting work welcomed

 

[mfgenggear]

Boltwasher
A small business MRP system. With a punch in clock. That requires the employees to punch each operation. There are many ways to set this up.
Each employee has a punch card or a mdi #.
There can be a simple operation sheet with bar code. Just like they scan items at a grocery store. All production of each assembly, sub assembly. And each part. Could be tracked, and viewed for what's in stocks.
systems can be proprietary or open source.

 

[Compositepro]

Is the worker's job to make product or to record data for management so they can operate a just-in-time inventory system? Most small companies just maintain a reasonable amount of inventory. Its a cost/benefit balance. Will a one employee company benefit from an MRP system? No.

 

[shreejisteel]

Tracking production progress is crucial for ensuring efficiency, meeting deadlines, and maintaining quality standards. Here are several options for tracking production progress that can be adapted to different manufacturing environments:

1. Manual Tracking Systems
Pros:

Cost-effective for small-scale operations.
Easy to implement with minimal training.
Cons:

Prone to human error.
Time-consuming and labor-intensive.
Examples:

Whiteboards: Used to list daily production goals, tasks, and progress.
Paper-based Logs: Workers manually record start and finish times for each task.
2. Spreadsheet Software
Pros:

Customizable to specific needs.
Easy data analysis with built-in functions.
Cons:

Can become complex and unwieldy as the scale of production increases.
Data entry errors can affect accuracy.
Examples:

Microsoft Excel: Used to create templates for tracking production stages, inventory, and timelines.
Google Sheets: Offers real-time collaboration and access from multiple devices.
3. Production Management Software
Pros:

Automates data collection and reporting.
Integrates with other business systems (e.g., ERP, CRM).
Cons:

Higher initial cost and training required.
Complexity can be overkill for very small operations.
Examples:

JobBOSS: Tailored for job shop manufacturing, offering real-time tracking and reporting.
Odoo Manufacturing: An open-source ERP solution with comprehensive production tracking features.
4. Enterprise Resource Planning (ERP) Systems
Pros:

Provides a centralized platform for managing all aspects of production.
Real-time data and analytics enhance decision-making.
Cons:

Expensive and complex to implement.
Requires significant training and change management.
Examples:

SAP ERP: Comprehensive solution covering production planning, scheduling, and execution.
Oracle ERP Cloud: Offers integrated modules for manufacturing, supply chain, and financial management.
5. Manufacturing Execution Systems (MES)
Pros:

Real-time monitoring and control of the shop floor.
Enhances traceability and compliance with quality standards.
Cons:

Can be expensive and complex to set up.
May require customization to fit specific production processes.
Examples:

Siemens Opcenter: Provides detailed tracking and management of manufacturing operations.
Rockwell FactoryTalk: Offers comprehensive production monitoring and control.
6. IoT and Sensor-based Tracking
Pros:

Provides real-time data and insights.
Reduces manual data entry and errors.
Cons:

High initial investment for hardware and software.
Requires integration with existing systems.
Examples:

Smart Sensors: Monitor equipment performance, production speed, and environmental conditions.
IoT Platforms: Collect and analyze data from connected devices to track production metrics.
7. Kanban Systems
Pros:

Visual and intuitive method for tracking progress.
Supports just-in-time production and reduces waste.
Cons:

May not be suitable for complex production processes.
Requires disciplined adherence to principles for effectiveness.
Examples:

Physical Kanban Boards: Use cards or tokens to represent tasks and track their progress.
Digital Kanban Tools: Software like Trello or Jira to visualize and manage production workflows.
8. Lean Manufacturing Techniques
Pros:

Focus on continuous improvement and waste reduction.
Enhances efficiency and productivity.
Cons:

Requires a cultural shift and commitment to lean principles.
Implementation can be time-consuming.
Examples:

Value Stream Mapping: Identifies and tracks value-added activities in the production process.
5S Methodology: Organizes the workplace for efficiency and effectiveness.
9. Automated Production Monitoring Systems
Pros:

Provides real-time insights into production status.
Reduces downtime with predictive maintenance alerts.
Cons:

High initial cost and setup complexity.
May require specialized knowledge to interpret data.
Examples:

SCADA Systems: Supervisory control and data acquisition for real-time monitoring and control.
PLC Systems: Programmable logic controllers for automated control of machinery.
10. Project Management Tools
Pros:

Centralizes project planning, scheduling, and tracking.
Enhances communication and collaboration among team members.
Cons:

May require adaptation to fit manufacturing processes.
Some tools can be expensive for small businesses.
Examples:

Microsoft Project: Comprehensive project management software with Gantt charts and resource tracking.
Asana: Task and project management tool with customizable workflows.
Each option has its strengths and weaknesses, and the best choice will depend on the specific needs and scale of the production environment. Combining multiple methods may provide a more comprehensive solution for tracking production progress effectively.

 

[CarlosGarza10]

I work for a company called Guidewheel, which is pretty good at tracking machine utilization and production.