American Manufacturing Strategies Summit
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The document presents a summary of a presentation by John Maher on creating a demand-driven factory of the future, highlighting five key elements that drive flow in manufacturing: controlling release, synchronizing activities, continuous improvement, extending to the supply chain, and aligning metrics. It emphasizes the importance of technology in facilitating real-time data-driven decisions and providing an integrated view of operations within an Industry 4.0 framework. Three case studies detail practical applications of these strategies in various manufacturing contexts.
American Manufacturing Strategies Summit
- 1. 1synchrono.com 1synchrono.com American Manufacturing Strategies Summit
- 2. 2synchrono.com 2synchrono.com Enabling the Demand-Driven Factory of the Future
- 3. 3synchrono.com 3synchrono.com About Your Presenter John Maher VP Product Strategy, Synchrono® • 20+ years’ experience working in manufacturing environments. • Subject matter expertise in ERP, MRP, APS, supply chain, manufacturing planning and scheduling systems and constraints management. • APICS CPIM certification in production and inventory management. • Jonah certification in Theory of Constraints from the Goldratt Institute.
- 4. 4synchrono.com 4synchrono.com Creating the Demand-Driven Factory of the Future Presentation Overview: • Crossing the chasm from Push to Pull • Technology as an enabler • What is Industry 4.0 and what does the factory of the future look like? 101010101 010101101 111010101 000101010 010101010 101010100 000011101 001101010 110101010 101010100
- 5. 5synchrono.com 5synchrono.com “Watch your thoughts; they become words. Watch your words; they become actions. Watch your actions; they become habit. Watch your habits; they become character. Watch your character; it becomes your destiny.” - Lao Tzu
- 6. 6synchrono.com 6synchrono.com 5 Key Elements to Drive Flow 1. Control the release (Pull) 2. Synchronize activities 3. Continuous improvement 4. Extend to supply chain 5. Align metrics 6synchrono.com
- 7. 7synchrono.com 7synchrono.com 1. Control the Release (Pull) • Clear the traffic jams • Turn on the lights and see for the first time • Pace to what the system needs and can handle 7synchrono.com
- 8. 8synchrono.com 8synchrono.com 2. Synchronize Activities • Optimize flow not local efficiencies • Subordinate local needs to global effectiveness (Inject your own sports analogy – they all apply) • Labor, material, machine, method 8synchrono.com
- 9. 9synchrono.com 9synchrono.com 3. Continuous Improvement (Based Upon Flow) • How do you direct your CI efforts? • Who is responsible for CI? • How do you avoid stagnation at another level? 9synchrono.com
- 10. 10synchrono.com 10synchrono.com 4. Extend to Supply Chain • Synchronize from the factory out • Proactive communication • Forecast for long-term planning; consumption for execution • Put an end to the emails and phone calls to reshuffle priorities and check status (non-value) 10synchrono.com
- 11. 11synchrono.com 11synchrono.com 5. Align Metrics • “Tell me how you will measure me and I will tell you how I will behave” • Metrics have to align with systemic flow, not local optima • Positive reinforcing loop 11synchrono.com
- 12. 12synchrono.com 12synchrono.com Why Technology HAS to be Part of a Demand-Driven Strategy • Manual is wasteful • Technology is the only way to take an enterprise view • Real-time only exists in the digital realm • Data-driven decisions cannot exist without data • One version of the truth
- 13. 13synchrono.com 13synchrono.com Model for Industry 4.0 Factory of the Future • Visual • Mobile • Integrated • Real-time
- 14. 14synchrono.com 14synchrono.com What Does Industry 4.0 Really Look Like? Case 1: Large A&D Manufacturer • Integrated Platform – ERP, PLM, MES, Asset Management, QMS, Labor Management synchronized with: • Planning/scheduling system • Data collection/workflow automation system • Alert/escalation system • Visual factory information system • Integrated through SyncOperations – moving beyond just pushing data around • Connecting the shop floor; data from RFID, EMS, Machines, HMI contextualized and historized
- 15. 15synchrono.com 15synchrono.com What Does Industry 4.0 Really Look Like? Case 2: High-Temp Vacuum Molded Parts Company • Sales representatives enter orders into ERP, which does a real-time call to the PSE system for effective CTPD • No schedulers! • True employee empowerment through PSE • Main metric and bonus system driven based on throughput
- 16. 16synchrono.com 16synchrono.com What Does Industry 4.0 Really Look Like? Case 3: Materials testing and extrusion-control instrumentation manufacturer • eKanban solution integrated with ERP • Buyers converted to strategic procurers • Suppliers net time savings by eliminating churn of communication • Real-time right-sizing of inventory Germany USA - 2 USA - 1 USA - 3 Malaysia SUPPLIERS SUPPLIERS SUPPLIERS
- 17. 17synchrono.com 17synchrono.com “CIOs of asset-intensive companies are finding themselves at the leading edge of industrial analytics, the next wave of business transformation. They surmount the existing challenges of IT/OT data integration and analysis by examining opportunity, business needs and skills availability.” - Simon Jacobson, Gartner
- 18. 18synchrono.com 18synchrono.com Read John's blogs Meet the Management Team [email protected] Demand-Driven white papers and case studies at synchrono.com To Learn More:
- 19. 19synchrono.com 19synchrono.com Stay in sync Synchrono® is a dynamic, growing company – in the news and on the move; innovating real-time demand- driven manufacturing solutions. We invite you to follow us and stay in sync.