Move Toward Zero Waste

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Production Planning and Scheduling Basics

In simple terms, Finite Capacity Scheduling is a method of scheduling used to maximize the usage of your assets based on the materials and orders you have on hand.  Typically the most expensive, and thus the most valuable resource in your facility is your equipment.  Each piece of equipment has a limited or finite capacity, and the goal is always to maximize usage of these resource.

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Customer Service is not Dead

When I started R.O.Why, my whole vision was (and is) to find ways to contribute to my customers’ success - surround myself with like-minded employees and affiliate R.O.Why with companies and rep firms that share my vision.  Whenever I talk about it, people get excited, you can see it in their face.  This kind of behavior is all around me too. In September, I stopped by the accounting firm I use -  Wetzel CPA group  to answer a tax question and ended up in a conversation with Ed Wetzel.  Ed’s firm has handled R.O.Why and my personal taxes for years and he has become a trusted advisor.  The Services page of his CPA website highlights “Tax Consulting, Planning & Preparation” and then at the bottom of the page he glosses over a list of other services.  At the top of that list you will find the key differentiator to a business owner like me - Strategic Business Plan development and Financing alternatives analysis & presentation to financial institutions.  Those services read like an afterthought on the site, but Ed is not just some bean counter.  He has served as CFO in a manufacturing environment for years and while the people at his firm (Jane, Nan, Brandon and Brenda) are exactly who I want to represent me in Tax Consulting, Planning & Preparation – this experience as CFO in manufacturing gives him an insight into the needs of small businesses that goes far beyond tax consulting.  If you need taxes done...go to Wetzel. If you want a small business owner, who also happens to serve as CFO to a medium size manufacturer, who also has a vision to contribute to his clients success…GO TO Wetzel.

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Large Controls upgrade projects don’t have to be high risk to be high reward.

Large Controls upgrade projects don’t have to be high risk to be high reward.

Case Study: CNC Retrofit - 140 axes in 80 days

An automaker manufacturing transmissions in North America, uses dial machines to drill and mill pump and reaction shaft supports. The machines were well maintained mechanically, and still very process capable; however the circa 1988 motion controllers and Programmable Logic Controllers were failing more frequently, and were becoming increasingly difficult to repair and support. As downtime was growing, the demand for the machined parts was increasing too. This automaker needed a control system retrofit that could be executed on their floor with minimum lost production. This is where good project management and a standard execution methodology was put to the test.

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Goals of Overall Equipment Effectiveness

Goals of Overall Equipment Effectiveness (OEE) OEE is a proven metric used in manufacturing to achieve three goals:
1.  Benchmark
2.  Improve
3.  Maintain improvementsSince OEE is used in very different and unique manufacturing processes, understanding how OEE is used in each process is critical to achieving these goals.
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An unexpected move Toward Zero™

Last year, a tier 1 automotive supplier moved Toward Zero™ unplanned downtime by implementing a system to monitor machine tool performance. The results were surprising.

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Ingredients of Giveaway Reduction

The Challenge:

A food ingredient company in the Midwest was losing product in there manufacturing process, but couldn't see where the product was going.

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Pumping the data

The Challenge:

An automotive transmission pump manufacturer was experiencing frequent micro-downtime events with an unknown cause.  The machine tool would would stop producing with no clear indication why.  Operators required technicians to reset and restart the equipment and it's peripherals and after a few hours, experienced the same situation...reset, restart. This cost operators about 1 hour per shift. The plant runs 24 hours a day, 6 days per week.

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Arch IoT leadership recognized by Kepware

Arch has been recognized for it's Internet of Things (IoT) leadership by being named a Kepware Silver System Integrator.

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