Paperless shop floor 01

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implementation of a paperless environment to support a manufacturing shop floor

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Paperless shop floor 01

  1. 1. PPaappeerrlleessss SShhoopp FFlloooorr
  2. 2. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 1. We are not sure the last router instructional change was received OR the obsolete instruction was removed ?
  3. 3. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 2. We have many versions of hard copy CAD drawings FOR THE SAME PART.. Removal of obsolete versions not guaranteed.
  4. 4. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 3. We have problems with printed forms and handwritten input: Data errors – no enforceable edits Illegible handwriting Untimely collection / reporting
  5. 5. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 4. Our routings, CAD drawings, and quality f o r m s a r e ‘ b o r n d i g i t a l ’ bbuutt tthheeyy aarree pprriinntteedd ffoorr sshhoopp fflloooorr uussee
  6. 6. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 5. We want video based work instructions but don’t know how to start
  7. 7. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 6. Our employees rely on handwritten notes on printed instructions
  8. 8. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 7. Our shop floor transactions are complex a n d t i m e c o n s u m i n g .
  9. 9. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 7. Our shop floor transactions are complex and time consuming. We need bar code technology to simplify, save time and eliminate errors.
  10. 10. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 8. Training our new employees is ongoing, requiring mentoring from more experienced employees We need to improve training methods
  11. 11. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 9. We are not confident obsolete documentation was removed from all filing cabinets
  12. 12. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 1100.. Our business requires signature approvals. Can electronic documents comply ? PPPPllllaaaannnntttt WWWWoooorrrrkkkk IIIInnnnssssttttrrrruuuuccccttttiiiioooonnnn
  13. 13. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 1111.. Our instructions aren’t updated frequently because of the cost and time involved Printers – ink cartridges - paper
  14. 14. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 1111.. Our instructions aren’t updated frequently because of the cost and time involved Cabinets (storage space / cost)
  15. 15. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ?? 1111.. Our instructions aren’t updated frequently because of the cost and time involved Replace old instructions with updates
  16. 16. CCoonnvveerrssiioonn TToo PPaappeerrlleessss Step-by-Step: 1. 1111.... Purchase Adobe Acrobat software. Convert documents (work instructions, CAD drawings) to PDF. PPoorrttaabbllee DDooccuummeenntt FFoorrmmaatt Developed in 1993 by Adobe Systems
  17. 17. PPPPDDDDFFFF:::: CCoonnvveerrssiioonn TToo PPaappeerrlleessss Captures text, fonts, graphics from a variety of software Documents can be sent to any PC or printer Is independent of application software, hardware, or operating system.
  18. 18. CCoonnvveerrssiioonn TToo PPaappeerrlleessss DDooccuummeenntt CCoonnvveerrssiioonn MSOffice (Word, Excel) Any software with a ‘Print’ function can be converted to PDF
  19. 19. Step-by-Step: 2. 2222.... Purchase / install hardware (PCs, monitors, bar code scanners) on shop floor CCoonnvveerrssiioonn TToo PPaappeerrlleessss
  20. 20. CCoonnvveerrssiioonn TToo PPaappeerrlleessss Step-by-Step: 3333.... 3. Create training material – train SF employees
  21. 21. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 1. PDF is the industry standard for viewing documents on . . . Smart phones Tablets Desktops Laptops
  22. 22. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 2. Adobe PDF Reader is FREE ANY computer can view PDF files
  23. 23. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 3. PDF reduces file size – files open quickly Example: Work instruction 4. Adobe PDF Reader supports document security: Prohibits altering documents Can be setup to prevent printing 354 KB 120 KB
  24. 24. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 5. PDF solution can be independent of, or support ERP software (Oracle, JD Edwards, SAP) 6. PDF has easy-to-learn navigation / viewing tools Page Navigation First-Prev-Next-Last Page Zooming / Magnifying
  25. 25. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF PDF supports bookmarks Bookmarks go directly to desired page (Ex: router op sequences)
  26. 26. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF PDF supports bookmarks and links to view other files PPllaanntt WWoorrkk IInnssttrruuccttiioonn 559999--8888--0022 RReevv BB CClliicckkiinngg hhyyppeerrlliinnkk ooppeennss ddooccuummeenntt
  27. 27. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF PDF supports bookmarks and links to view other files CCAADD ddrraawwiinngg ((22DD oorr 33DD)) iiss ddiissppllaayyeedd
  28. 28. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF PDF ‘zooming’ tools are excellent WWeeaarr aapppprroovveedd gglloovveess wwhheenn hhaannddlliinngg tthhee ppaarrtt.. Using the zoom icon, draw a box around the area to be magnified
  29. 29. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF PDF ‘zooming’ tools are excellent
  30. 30. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 9. PDF supports digital signatures with password control PPPPllllaaaannnntttt WWWWoooorrrrkkkk IIIInnnnssssttttrrrruuuuccccttttiiiioooonnnn
  31. 31. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 9. PDF supports digital signatures Signature location defined by drawing a box on document Format of signature block defined by approver Signature history resides with document
  32. 32. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 10. PDF supports document keyword searching Example: Find all instructions for ‘6504.31’
  33. 33. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 10. PDF supports document keyword searching
  34. 34. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 11. PDF supports electronic forms Design – Distributing - Data Collection - Reporting DDeessiiggnn ffoorrmm ttoo iinncclluuddee:: Calculations DDaattee sseelleeccttiioonn ffrroomm ccaalleennddaarr LLiisstt ooff vvaalluueess CChheecckk bbooxxeess RRaaddiioo bbuuttttoonnss DDiiggiittaall ssiiggnnaattuurreess DDeecciimmaall pprreecciissiioonn MMaannddaattoorryy // ooppttiioonnaall AAdddd bbaarrccooddeess SSppeellllcchheecckkiinngg
  35. 35. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF 11. PDF supports electronic forms Design – Distributing - Data Collection - Reporting EEddiittss EEE EEE EEE EEE EEE EEE EEE EEE
  36. 36. PPrreesseennttaattiioonn OOppttiioonnss If minimal job instructions – create a table with hyperlinks Clicking hyperlink displays the proper job instruction
  37. 37. PPrreesseennttaattiioonn OOppttiioonnss If many job instructions – add barcode to job router AACCEE MMAANNUUFFAACCTTUURRIINNGG Clicking bar code displays the proper job instruction
  38. 38. IImmpplleemmeennttaattiioonn CCoossttss Required Network document storage with acceptable employee access
  39. 39. IImmpplleemmeennttaattiioonn CCoossttss Software Costs Viewing documents Acrobat PDF Reader Free Creating documents Adobe Acrobat Purchase 1 license per creator New license Upgrade AAAAccccrrrroooobbbbaaaatttt 11111111 $$ $$ $$ $$
  40. 40. IImmpplleemmeennttaattiioonn CCoossttss Software Costs Adobe Acrobat Professional only Subscription plans 1 license for 2 PCs AAAAnnnnnnnnuuuuaaaallll PPPPllllaaaannnn $$1199..9955 // mmoo BBiilllleedd AAnnnnuuaallllyy $$226600 MMMMoooonnnntttthhhhllllyyyy PPPPllllaaaannnn $$2255 // mmoo $$330000 // yyrr AAddvvaannttaaggee:: FFrreeee UUppggrraaddee ttoo NNeeww RReelleeaasseess
  41. 41. AAccrroobbaatt SSttaannddaarrdd vvss.. PPrrooffeessssiioonnaall PPrrooffeessssiioonnaall vveerrssiioonn iinncclluuddeess ffuunnccttiioonnaalliittyy ttoo:: 1.Assemble many file types into polished, organized PDF ‘Portfolio’. Includes layouts and visual themes. 2.Permit Acrobat Reader users to: Participate in shared reviews with commenting / markup tools
  42. 42. AAccrroobbaatt SSttaannddaarrdd vvss.. PPrrooffeessssiioonnaall PPrrooffeessssiioonnaall vveerrssiioonn iinncclluuddee ffuunnccttiioonnaalliittyy ttoo:: 1.Assemble many file types into polished, organized PDF ‘Portfolio’. Includes layouts and visual themes. 2.Permit Acrobat Reader users to: Participate in shared reviews with commenting / markup tools Digitally sign PDF documents / forms
  43. 43. AArree EElleeccttrroonniicc FFoorrmmss iinn SSccooppee ?? Software Costs Adobe LiveCycle Designer $299 per license
  44. 44. IImmpplleemmeennttaattiioonn CCoossttss HHaarrddwwaarree UUnniitt CCoossttss Desktop PC Touch screen monitor $ 300 $ 350 23” screen Requires Windows 7 or later RRRReeeevvvviiiieeeewwww
  45. 45. IImmpplleemmeennttaattiioonn CCoossttss HHaarrddwwaarree UUnniitt CCoossttss Touch screen monitor Solution Pros: 1) Portability 2) Don’t have to buy 1 for 1 RRRReeeevvvviiiieeeewwww $ 350 23” screen Laptop $ 300 - 350 Requires Windows 7 or later
  46. 46. IImmpplleemmeennttaattiioonn CCoossttss HHaarrddwwaarree UUnniitt CCoossttss Bar Code Scanner Wireless $ 375 Wired $ 114
  47. 47. IImmpplleemmeennttaattiioonn CCoossttss PPoossssiibbllee EEnnvviirroonnmmeennttaall CCoossttss PC enclosures
  48. 48. IImmpplleemmeennttaattiioonn CCoossttss PPoossssiibbllee EEnnvviirroonnmmeennttaall CCoossttss Monitor / laptop covers Wireless evaluation Determines wireless equipment needs based on coverage area and equipment interference issues
  49. 49. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss Current versions of SF documents always available
  50. 50. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss Eliminates time / cost spent printing, distributing, filing and retaining paper
  51. 51. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss Bar coding facilitates faster data collection, lower costs and reduced human keying errors
  52. 52. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss Easy-to-access video opens up a new SF instructional media Engineering time and costs reduced for version control and document signoff
  53. 53. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss Improve employee training by having all SF information available online
  54. 54. SSuummmmaarryy RReeaassoonnss TToo CCoonnvveerrtt NNooww Hardware is proven. Many low cost options exist. Wireless technology is proven. No need to ‘hard wire’ PCs. Easy SF physical reorganization.
  55. 55. SSuummmmaarryy RReeaassoonnss TToo CCoonnvveerrtt NNooww PDF is the: Industry standard for viewing documents Low cost alternative to document management software
  56. 56. SSuummmmaarryy Hardware, software and wireless technology is proven and works well together
  57. 57. SSuummmmaarryy Key to a successful project: Fostering and managing organizational change
  58. 58. MMoovvee TToo 2211sstt CCeennttuurryy MMaannuuffaaccttuurriinngg Scrap Paper
  59. 59. MMoovvee TToo 2211sstt CCeennttuurryy MMaannuuffaaccttuurriinngg Scrap Paper Go Paperless
  60. 60. MMoovvee TToo 2211sstt CCeennttuurryy MMaannuuffaaccttuurriinngg Scrap Paper Go Paperless Years of Experience: 36 - Information Systems 17 - ERP (Mfg / Distribution / Bar Code) 11 - Business Intelligence Reporting
  61. 61. PPaappeerrlleessss SShhoopp FFlloooorr DDeemmoo

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