How can you implement closed-loop manufacturing?

It is fundamental to have a stable and reliable manufacturing process before closed loop implementation can begin. This is especially important in the world of machining where process driven issues can cause a lot of noise and variability. Stochastic behavior will only be amplified through a closed loop architecture. Hence it is important to root out all possible process issues before thinking of automating the feedback loop.

Clear goals and objectives are foundational for successful implementation of closed-loop manufacturing. These goals provide a roadmap for addressing key challenges and seizing opportunities within manufacturing operations. By setting specific targets, such as reducing defects, increasing efficiency, lowering energy consumption, or enhancing customer satisfaction, organizations can focus their efforts and resources effectively. Additionally, considering regulatory and market demands is crucial to ensure compliance and responsiveness to external factors that may impact manufacturing processes. By articulating these goals, organizations align their vision and strategy, enabling them to measure progress and performance accurately.

Begin by establishing clear goals using the SMART principle. Focus on the primary issues you want to address, such as waste reduction or enhanced efficiency. Pinpoint the data sources essential for decision-making. Look within your production lines for machine data, quality reports, and inventory information. Prioritize data accuracy and reliability. Design feedback loops with Key Performance Indicators (KPIs) that align with your goals. Define thresholds within these KPIs that will activate corrective measures. Embrace the Plan-Do-Check-Act (PDCA) cycle for ongoing improvement. Nurture a company culture that celebrates learning, experimentation and recognition.

Foco na Qualidade: Redução de Defeitos Uma meta fundamental para qualquer empresa é a redução de defeitos em seus produtos ou serviços. Defeitos representam não apenas custos financeiros associados a retrabalho e substituições, mas também podem comprometer a reputação da marca e a satisfação do cliente. Ao estabelecer a meta de reduzir defeitos, uma organização demonstra seu compromisso com a qualidade e a excelência em cada etapa do processo de produção ou prestação de serviços. Implementar programas de controle de qualidade robustos, como Seis Sigma ou Total Quality Management (TQM), pode ajudar a identificar e eliminar fontes de defeitos, promovendo a melhoria contínua em toda a cadeia de valor. Além disso, investir em tecnologias.

We need to reduce the wastage, chemicals usage in processing, defects, utility consumption, idle time and reprocess. It will give less materials to process for reuse which is very much costly than regular manufacturing. Otherwise the product cost will be high and closed loop manufacturing may not be sustainable!

Je propose d'ajouter les points suivants: -instaurer une politique de maintenance conditionnelle, -Integer et implémenter les outils de la MSP

Make sure everywhere you get information from has some backing or certification to it/them. Make sure that there is photographic evidence or written evidence for everything you choose to follow. Define: What is it? Where did this come? What is the authority? How can we use this? Is this better or worse than x or y? How can we use this to grow the company? (Financial, productivity, flash/pizzaz to impress the higher ups) Make sure you get a referral for everything/most things. It’s always something to fall back onto in case that something falls short of perfection.

Il y'a aussi : - les données de maintenance du produit : Historique des maintenances préventives et correctives. Temps d'arrêt dû à des pannes ou des réparations. Coûts associés à la maintenance des équipements - les données de qualité: Rapports d'inspection de qualité et de conformité. Taux de défauts et types de défauts rencontrés. Retours et réclamations des clients. Résultats des tests de durabilité et de performance

Ponto importante aqui, antes de definir as fontes, definir quais os dados que realmente serão relevantes a cada step. Envolver clientes logo nos primeiros steps pode não ser algo muito interessante para corporação. Muitas vezes também, já vi casos de buscarem muitos dados que não eram relevantes e acabam por poluir suas informações.

In organisation large amount data available most important usage of this respective data & data analytics which always use for real taking decision making key success for organisation. Various types of analytics tools helping organisation like Tableau matrix, Advanced planning Software,Heat Mapping , scattered diagram & usage of many AI tools helping real time availablity.

Lo importante es definir bien los objetivos para saber el rumbo del proyecto y evitar las pérdidas de tiempo, actividades innecesarias Además de realizar feedback al equipo para ver el cumplimiento de los mismos

To get the benefits of both positive and negative feedback loops, organizations should foster a culture of open communication and transparency, encouraging employees at all levels to share their insights and opinions. As feedback very important for any process , product, safety & Quality improvement.

To bring closed-loop manufacturing to life, start by nurturing a culture of continuous improvement (CQI). Encourage your team to embrace learning at every turn and celebrate their achievements along the way. When someone deserves praise, give it freely – recognition fuels motivation. By fostering an environment where growth is valued and acknowledged, you create the groundwork for a sustainable closed-loop system. Remember, it's not just about processes; it's about people too. With a dedicated focus on improvement and a supportive team ethos, closed-loop manufacturing becomes more than a concept – it becomes a living, breathing reality in your workplace.

Aqui o grande passo através da evolução de sua maturação. Aqui podemos incluir novos dados a serem visitados, novos stakeholders a serem envolvidos, e certamente revisão das metas de sua implementação.

Surely high beneficial Program I witnessed i ran for 1 yr in a MNC Being involving cross functional all levels some great improvement got without investment M Ganapathi Sankar 9764001528

The implementation of continuous improvement in any process is performed by following measuring and improving phases, Measuring your process: Start by measuring everything and then focus on where the problems are. To verify the data use of ratio and comparison analysis are effective. SPC are one of the important tools applied in your measuring process. Improving the Process: Improving your process means optimizing Quality, Cost and Time. There are some costs associated with this, prevention costs, failure costs and reducing waste costs. Finding Bottlenecks of the system and providing solutions to avoid or reduce the impact. The pull approach is a proven technique for process improvement (Kanban Ordering System).

3 important things about closed loop implementation in manufacturing: 1.There is ocean of data available in manufacturing. We need to be very particular about what data we need for feedback to have greatest impact on the output that is key for customer delight. 2. The feedback data needs to be acted upon very fast to reduce the negative impact of deviation of the metric from target.Otherwise there is no use of the effort we put for getting the feedback data. 3.Data regarding field failure due to manufacturing needs to reach the production area right upto the operator level at the earliest. Rather there should be a rule about in how much time any product failure at any stage must reach the station where defect was generated.

1.Closed loop benefit comes when the corrective action takes place as per the feedback. 2.There should be minimum time lag in the closed loop. Otherwise by the time correction happens, lot of defects would have been generated which need to be reworked or scraped totally, nullifying the intent of deploying closed loop. 3.Too much data collection for feedback will be a huge hindrance for taking proper corrective action. So good time must be spent at the starting in deciding what are all the minimum necessary data that needs to be collected.

Il serait aussi avantager de: - investir dans la formation de vos équipes pour s'assurer qu'elles ont les compétences nécessaires pour exploiter les données et mettre en œuvre des changements. - Collaborer avec vos fournisseurs, clients, et d'autres partenaires pour partager les connaissances et optimiser l'ensemble de la chaîne de valeur.

Its manufacturing without waste. Transitioning to close loop manufacturing is key to sustainability 1. Audit Your Process: Identify inputs and outputs with focus on product lifecycle for improvement areas. 2. Design Smart: Opt for modular design and sustainable materials and modular designs to prolong product life. 3. Recycle and Reuse: Implement both internal and external recycling strategies. 4. Optimize Production: Embrace lean manufacturing and energy efficiency. 5. Collaborate: Work closely with suppliers on sustainable practices. Educate customers and engage in meaningful partnerships for a broader impact. 6. Monitor and Improve: Keep track of your sustainability efforts, report on progress, and continuously seek improvement.

Closed loop feedback implementation is expensive and works well as when there is too much variability in many parameters of a process. Open loop feedback implementation is inexpensive when there is a pattern or a repeatable trend in the variability. With prevalence of new age CNC systems in manufacturing open loop system can save millions in capital deployed apart from savings due to better process capability.