Lean Materials Management
Business Benefits of FactoryLogix Lean Materials Management
A quality, efficient manufacturing process requires raw materials to arrive at the right location at the right time. FactoryLogix monitors and reacts automatically to materials demand from the lines, manages line changeover, assures proper setups, and provides ERP unprecedented visibility to quantities factory-wide, for the most effective materials management and material requirements planning (MRP).
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FactoryLogix Lean Materials Management
Feeder setup changeovers impact equipment utilization and ultimately overall equipment effectiveness. It is a fairly complex task to realistically plan build orders and allocate them to the available production lines with a minimization of changeovers. FactoryLogix’ line changeover optimization solutions address these challenges. With awareness of the available machines and the lots to be produced, it determines setup groups that are then distributed to the appropriate lines. As a result, each line has an ideal setup. In order to attain these results, FactoryLogix knows all the machine parameters to the letter and is thus in a position to adjust setup programs for individual boards, so that setup clusters are created across a variety of assemblies without a single change-over.
Before material can be verified on the floor and ultimately provide product content traceability, each received material instance must be properly labeled and identified. Whether labeled prior to or after receipt, FactoryLogix offers a variety of highly automated solutions for capturing and identifying each item, down to its lot number. It offers intelligent operator guidance for scanning specific vendor labels, where their content and sequence varies from vendor to vendor. New labels may be generated for each item for consistent labeling of all stocked material. For material registered in external systems, FactoryLogix also offers integration solutions for direct acquisition of received material.
Minimizing stock levels is a key driver for controlling inventory costs, although it breeds greater challenges. It often limits sufficient reaction time for urgent orders with greater material needs in the short term, and this issue increases for components with longer lead times. Moreover, additional purchases may be unnecessary but the lack of true production visibility makes the components difficult to locate on the floor. Warehouse management is core to FactoryLogix’ logistics support, providing material and location awareness with knowledge of each material’s existence, stock location, and its present quantity. Through integration, it provides efficient and instant delivery of kitted material from automated carousels and towers. Material awareness stretches across the factory and its assembly lines, where components that should be available with a sufficient build quantity are in use somewhere else on the floor.
The inStock Mobile Material Management app merges the power of our FactoryLogix Logistics solution with a durable, easy-to-use Motorola MC40 Handheld Computer. With inStock, users can scan and search for stock and retrieve material on demand and at the point-of-use; no more referring back and forth to a distant terminal. Instead, inStock operators are guided through the kitting process with digital pick lists that are grouped by their destination on the factory floor, and sorted for efficient picking in the stock area. Providing stockroom personnel with instant access to the information they need saves considerable time and costly labor.
More and more moisture sensitive devices find their way into the electronics manufacturing. These devices are divided into different JEDEC level classes, according to the IPC/JEDEC J-STD-020C standard. The level determines how long a component may remain unpackaged and open in a normal humid environment until it is rendered unusable. Moisture sensitive devices (MSD) require proper handling and storage prior to its use in assembly. FactoryLogix supports the process of storing moisture-sensitive material in dry storage or bake ovens as well as tracking its removal.
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