Factory Control Systems News
AlphaCAM & Factory Control Systems 28/10/2008
For many years now AlphaCAM specialist software engineers have been in the fore front of CNC programming and its development for advanced machining. To compliment their machine control software and give their customers even greater control of production AlphaCAM embarked on the development of a suite of management software "AlphaCIM".
Whilst initially it was thought that these software systems would easily sit side by side, AlphaCAM have now realised that the development of AlphaCIM is taking up valuable resources that could better be used developing their core products and that the development of Enterprise Resource Planning (ERP) systems requires a company specialised in them.
Having successfully integrated AlphaCAM products with their own ERP system at a number of mutual customers, Factory Control Systems (FCS) were the logical partner to replace and expand on the AlphaCIM software suite.
FCS has developed an extensive suite of modular software that is designed to support and control any kind of furniture or timber based production, including bespoke production with parametrically adjusted "engineered to order" products. Full production and purchasing control is achieved through a MRP system that gives costings, material requirement and manufacturing resource requirement even for parametrically adjusted products.
Customer orders can be automatically "launched" into production to hit the required delivery date using FCS and then AlphaCAM software picks up the details and programmes the machines. All materials or hardware used are accounted for and if this causes stock levels to fall below a preset amount re-ordered in time for the next production run.
The main development team at FCS are all furniture industry professionals, as one customer commented, "Unlike other software companies we don't have to explain what an edgebander is or why we need to optimise for a beam saw, FCS already know". Support for the AlphaCIM product from AlphaCAM will end at the end of next year by which time both AlphaCAM and FCS are sure that existing users will be successfully migrated to the FCS ERP system.
The partnership between AlphaCAM and FCS will surely benefit their customers whilst at the same time allowing both companies to continue along their own, specialist, development paths.
Lean Manufacturing with Factory Control Systems 09/10/2008
Lean Manufacturing is based in delivering what the Customer wants when they want it with the secondary objective of reducing and where ever possible eliminating waste completely. Taiichi Ohno (of Toyota) defined 7 categories of "Muda" (waste), modern experts have added an eighth, the waste in skills. An easy way I learned at a seminar to remember the wastes is that their first letters spell TIM WOODS
T - Transport - Moving people, products & information Factory Control Systems gauges capacity by the staffing and/or output levels per machine or area, releases specific quantities of materials for that work and issues' works orders with tracking details to instruct the operators on what is requires, in which order and by when. The full system can be driven by distribution planning, where the delivery date, volume and weight of an order together with the delivery address create a vehicle load and sequence back from this to ensure that all the products are produce in reverse drop order (i.e. last on vehicle is first delivery).
I - Inventory - Storing parts, pieces, documentation ahead of requirements FCS can work in batch, build to order or mix mode manufacturing. Rules can be set to automatically change the manufacturing mode to suit the demand, the aim being to minimise stock and provide works orders or picking lists to support only what is required by the next operation in the line.
M - Motion - Bending, turning, reaching, lifting FCS minimises work by ordering the work in the optimum sequence for the area, i.e. grouping like items, processes, sizes or colours together to minimise down time and handling.
W - Waiting - For parts, information, instructions, equipment Because FCS take into account the capacity of the equipment or area and works back from delivery dates it only launches into production items that are actually required. Equipment will be available as we have run capacity planning and instructions, complete with any special details, will be on dedicated works order, to do lists or picking lists for each area.
O - Over production - Making more than is IMMEDIATELY required FCS in build to order mode only makes the required amount. FCS running in stock mode works off economic order qualities, lead time and minimum stock levels, which together with MRP runs on the system ensure stock and any over production is kept to a minimum.
O - Over processing - Tighter tolerances or higher grade materials than are necessary FCS can log problems raised by customers and tie them back to an area of manufacture or material. This as part of a continuous improvement programme guides the user to tighten specifications if required, or gradually reduce tolerances in a controlled way until faults levels are balanced in line with each other and the market accepted standard.
D - Defects - Rework, scrap, incorrect documentation FCS through a barcode system can track work and record defects per area, machine or person, with a reason code. This allows for later analysis and is ideal data collection for continuous improvement programmes.
S - Skills - Under utilizing capabilities, delegating tasks with inadequate training FCS can monitor scrap and defects per area this can highlight a lack of skills required to produce items of the correct quality and so point out training needs.
Contact Factory Control Systems to find out how we can help you along the way towards a lean future.