Case Studies Integration Increases Scrap Visibility, Drives Down Defects and Costs

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	Integration Increases Scrap Visibility, Drives Down Defects and Costs

Integration Increases Scrap Visibility, Drives Down Defects and Costs

Technology Category	Analytics & Modeling - Real Time Analytics Application Infrastructure & Middleware - Data Exchange & Integration Functional Applications - Enterprise Resource Planning Systems (ERP)
Applicable Functions	Process Manufacturing Quality Assurance
Use Cases	Machine Condition Monitoring Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration
Challenge	High-precision machining company Exacto Inc. tracked scrap data in their ERP system to monitor production and inventory. Once a month, Exacto leadership extracted scrap data into an Excel report for quality analysis. However, the process was cumbersome and the data was often four-to-six weeks old, making it almost useless for timely problem solving and process improvement. Leadership wanted the ability to do more with the ERP system data and wanted timely access to the data. Exacto was a longtime GainSeeker user for real-time shop floor SPC but had never implemented its powerful defect management system due to high labor costs. Manufacturing operations needed scrap data entered in the company’s ERP system to track WIP, inventory, and costing. The quality manager’s need for timely access to scrap data was left on a back burner and never moved forward. Read More
About Customer	Hertzler Systems provides seamless, accurate data acquisition solutions for business enterprises and has been in this business for over 30 years. Their customers buy software and services because it is a good investment. With Hertzler's assistance, clients can easily acquire data in any process, analyze that data in real time, and instantly notify process owners of process variation. These capabilities help clients reduce costs, cycle time, errors, and defects, and increase profitability and customer satisfaction. Hertzler Systems' core competencies include providing solutions that enable businesses to make data-driven decisions, thereby improving operational efficiency and overall performance. Read More
Solution	Hertzler Systems created an integration process between GainSeeker and the ERP system. The process automatically extracts scrap data from the ERP system and loads it into GainSeeker. Because the integration is automated, there is no additional labor cost to collect the data. The current practice is to extract the data daily, although it could be done more frequently. This integration allows the quality manager, engineers, and other manufacturing leaders to have daily access to scrap counts, defect reasons, and scrap costs. They can track costs for the same product at different points in the process and for different job runs. Exacto leadership can now quickly spot trends in the data and drill down to the root cause of scrap problems. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Real Time Analytics

Application Infrastructure & Middleware - Data Exchange & Integration

Functional Applications - Enterprise Resource Planning Systems (ERP)

Applicable Functions

Process Manufacturing

Quality Assurance

Use Cases

Machine Condition Monitoring

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Challenge

High-precision machining company Exacto Inc. tracked scrap data in their ERP system to monitor production and inventory. Once a month, Exacto leadership extracted scrap data into an Excel report for quality analysis. However, the process was cumbersome and the data was often four-to-six weeks old, making it almost useless for timely problem solving and process improvement. Leadership wanted the ability to do more with the ERP system data and wanted timely access to the data. Exacto was a longtime GainSeeker user for real-time shop floor SPC but had never implemented its powerful defect management system due to high labor costs. Manufacturing operations needed scrap data entered in the company’s ERP system to track WIP, inventory, and costing. The quality manager’s need for timely access to scrap data was left on a back burner and never moved forward.

About Customer

Hertzler Systems provides seamless, accurate data acquisition solutions for business enterprises and has been in this business for over 30 years. Their customers buy software and services because it is a good investment. With Hertzler's assistance, clients can easily acquire data in any process, analyze that data in real time, and instantly notify process owners of process variation. These capabilities help clients reduce costs, cycle time, errors, and defects, and increase profitability and customer satisfaction. Hertzler Systems' core competencies include providing solutions that enable businesses to make data-driven decisions, thereby improving operational efficiency and overall performance.

Solution

Hertzler Systems created an integration process between GainSeeker and the ERP system. The process automatically extracts scrap data from the ERP system and loads it into GainSeeker. Because the integration is automated, there is no additional labor cost to collect the data. The current practice is to extract the data daily, although it could be done more frequently. This integration allows the quality manager, engineers, and other manufacturing leaders to have daily access to scrap counts, defect reasons, and scrap costs. They can track costs for the same product at different points in the process and for different job runs. Exacto leadership can now quickly spot trends in the data and drill down to the root cause of scrap problems.

Impact #1	The quality manager, engineers, and other manufacturing leaders now have daily access to scrap counts, defect reasons, and scrap costs.
Impact #2	They can track costs for the same product at different points in the process and for different job runs.
Impact #3	Exacto leadership can now quickly spot trends in the data and drill down to the root cause of scrap problems.

Impact #1

The quality manager, engineers, and other manufacturing leaders now have daily access to scrap counts, defect reasons, and scrap costs.

Impact #2

They can track costs for the same product at different points in the process and for different job runs.

Impact #3

Exacto leadership can now quickly spot trends in the data and drill down to the root cause of scrap problems.

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Overview

Integration Increases Scrap Visibility, Drives Down Defects and Costs

Operational Impact