ArticlesArticles Most Helpful ArticlesMost Helpful Articles Language SettingsLanguage Settings LoginLogin
RSS Feeds
DrillDown Icon Table of Contents
DrillDown Icon MX
DrillDown Icon MANUALS and Other Info for SQL MANEX Client Server
DrillDown Icon Customer Relationship Management (CRM)
DrillDown Icon ManEx Minute
DrillDown Icon WireHarness Manufacturing
DrillDown Icon Alternate Parts
DrillDown Icon Outsource Management
DrillDown Icon Documentation Control
DrillDown Icon Supply Chain Management
DrillDown Icon Happy Holidays
DrillDown Icon Customer Credits
DrillDown Icon Publication Changes
DrillDown Icon System Triggers
DrillDown Icon Multi-shift communications
DrillDown Icon Find by Ref Desg
DrillDown Icon BoM Importing
DrillDown Icon Kitting By BoM
DrillDown Icon Minimum Buys and Residual Inventory
DrillDown Icon Customer Part Number Cross Referencing
DrillDown Icon Performance Tracking
DrillDown Icon Work Order Numbering
DrillDown Icon Inventory by Project
DrillDown Icon Counterfeit Components
DrillDown Icon WC Priorities and Scheduling
DrillDown Icon ManEx Minute - Attrition & Scrap
DrillDown Icon Business Case Solutions - 16
DrillDown Icon ManEx Solution - 16
DrillDown Icon ManEx Minute - Kitting
DrillDown Icon ManEx Minute - Assembly Revisions
DrillDown Icon ManEx Minute - Cycle Counting
DrillDown Icon ManEx Minute - Order Status Updates
DrillDown Icon ManEx Minute - Excess Inventory
DrillDown Icon ManEx Minute - MRP Filtering
DrillDown Icon ManEx Minute - Part Shortage Tracking
DrillDown Icon ManEx Minute - Reader Survey
DrillDown Icon ManEx Minute - Supplier Communication
DrillDown Icon ManEx Minute - Production Flexibility
DrillDown Icon ManEx Minute - AVL Management
DrillDown Icon ManEx Minute - Production Offsets
DrillDown Icon ManEx Minute - Obsolescence of MPN
DrillDown Icon ManEx Minute - Customer Owned Inventory
DrillDown Icon ManEx Minute - MRP Sharing
DrillDown Icon ManEx Minute - Announcement
DrillDown Icon Survey Results
DrillDown Icon ManEx Component Exchange
DrillDown Icon ManEx Supplier Directory & Rankings
  Email This ArticlePrint PreviewPrint Current Article and All Sub-Articles
 
ManEx Solution - 16 - Production Attrition & Scrap


ManEx Case Solution

ManEx has several standard and optional features designed to simplify the process of identifying, tracking, and eliminating attrition and scrap.  .

  • Cycle Count/Physical Inventory - built-in physical inventory and cycle counting features enable users to identify discrepancies.
  • Kitting Module - Closing a kit allows a user to select which components to count and provide actual attrition information, and which parts to accept default attrition settings and leave for cycle counting to update.
  • Job Costing - The optional job costing module gathers usage data for every part in the kit.  This makes it easier to identify excess attrition.  Users can also us it to analyze consumption across multiple jobs and review process changes for reductions in attrition.
  • ECO - If process changes are needed to reduce attrition and scrap, the ECO module is an excellent tool to document the changes, apply those changes to affected jobs, and communicate those changes to production.
  • Product Routing and Instructions - Users can increase the success rate of process improvements by documenting and distributing the improvements electronically.  Providing a central location for employees to access routings and instructions ensures they use the latest procedures and updated methods.
  • Statistical Quality Control - The optional quality module will allow companies to associate defects with reference designators, AVLs, part numbers, work centers, and employees.  This visibility not only provides the ability to identify sources of scrap, but also increase overall quality.
  • Custom Reporting - Users have the ability to create custom reports using any ODBC compliant report writer.  Using a program like Crystal Reports will enable distribution of those reports within ManEx.

In Process Upgrades 

  • IPKey Tracking - Companies electing to implement IPKey functionality will gain the benefit for more streamlined material tracking.  This will facilitate easier and faster identification of attrition and scrap sources.
  • Production Machine Interface - With the completion of the IPKey functionality, users will have the ability to establish communication with production machines.  This means consumption information and scrap data can be automatically loaded into ManEx.
 
CONCLUSION
 
NE Company has been implementing attrition reduction practices throughout the production process.  Over the last six months they were able to identify a machine with double the scrap rate, a work center with inadequate process instructions, and an issue with kitting processes that resulted in nearly a third of all attrition.  With minor adjustments to these and other areas, they reduced the weighted attrition to just under .5% and saved an estimated $45K a year in attrition and scrap. 
 
They continue to review their processes and practices and hope to be able to reduce attrition by another $10K per year by the end of the year.
Article ID: 3242