Scrap, Rework and Downtime can Significantly Impact Cost and Quality
It is a fact. Every company experiences scrap, rework and downtime. Unfortunately, many companies still don’t know how to predict and manage the impact of these events on their time, budgets, and quality.
Statistical Process Control (SPC) software helps companies improve quality by enabling shop floor operators, quality personnel, and management to spot, diagnose and correct defects and see trends that predict downtime before it occurs.
Synergy SPC software from Zontec provides instant access to quality data across the entire production process for real-time visibility into the manufacturing process. This data lets an organization take preventative action to correct process variation and prevent quality defects before they occur. This is likely to save your company a significant amount of money by reducing scrap, rework, and even downtime.
SPC Software Helps Reduce the Impacts of Downtime
Studies estimate the frequency and costs associated with manufacturing downtime. They typically include a variety of expenses including overhead, labor cost, scrap, equipment repair cost, lost production time, but typically don’t capture the total quality cost or the decline in customer confidence or even the cost to the customer when downtime leads to shipping delays.
It is safe to say, planned or unplanned, production downtime is always expensive. But, if you are using Zontec SPC software you are collecting real-time quality data and you can monitor critical characteristics that let you predict how a process is performing. This important information helps you lower many of the costs associated with downtime. This is how one Zontec customer, Cumberland Plastics Solutions, described it,
“We are daily able to monitor critical characteristics in an effective, real-time, proactive manner and predict if the processes or the tools are trending towards going out-of-control,” said Aditya Deshpande, Quality Assurance Manager for Cumberland Plastics Solutions.
Using SPC software to minimize downtime and manage costs over time will increase your profits to help your business. There is no reason to expose your company to expensive unplanned downtime when you can predict it and manage the costs using real-time data analytics available by using Zontec SPC software.
Reduce Scrap and Rework with SPC Software
Collecting and analyzing quality data using SPC software helps you reduce scrap as shown in this LMPsrl example,
“Since using Synergy 3000, we have reduced our scrap rate by 20%. We now know where we had waste in our process, realistic values to base our key performance indicators on, and how to improve our margins,” said Fedele D’Alessandro, General Manager for LMPsrl.
This example demonstrates how companies use SPC data to improve decision-making and taking corrective action to reduce production scrap and rework,
“Because we use SynergySPC software, United Gear and Assembly has the ability to effectively manage the lifecycle of its tools. Through the use of Run Charts and other Synergy tools we can determine tool life and predict how many parts can run before needing to make adjustments or change out the tool. We can budget our tool life management more accurately and effectively based on this data,” said Douglas Winfrey, Director of Quality, at United Gear and Assembly.
Real-time SPC software is a tool to help you monitor, document, identify and reduce variation to achieve a stable and capable manufacturing process. By truly understanding and eliminating sources of variation, you will dramatically reduce scrap and rework. Use SPC software data history to predict the future stability of the manufacturing process. This will give you confidence that your parts meet required specifications and standards. To see a Zontec software demonstration call 513-648-9695 or contact us at https://www.zontec-spc.com