• Aplications

All the companies that require certification in GMP (Good Manufacture Practices) must do process validation, since this process guarantees product quality for its consumption.

Why must we do this process? Because validation is the compilation and evaluation of gathered data, from the design stage to final production, where evidence that guarantees that the process complies with the quality is gathered.

What are the stages I need to follow?

Stage 1: Design of the process

Departing from design activities and development, manufacturing parameters are defined. This step in process validation can test multiple types of raw material, container materials, packaging, areas and so on that will allow to get the final result the customer is looking for.

Stage 2: Rating of the Process

In this stage of process validation, the design of the product is evaluated where it is going to identificate from a compilation of data if this has a replicable behaviour in a commercial way.

Stage 3: Continuous Verification of the process

To keep a constant verification to the process validation there has to be a constant verification. In the product manufacturing a routine verification remains to reassure that the process status is being controlled. One way of doing this is through process control cards.

Aplicaciones realidad virtual aumentada y mixta

Single-Minute Exchange of Die, is a tool that pretends to achieve time reduction in machine preparation and material exchange that are invested to make a format change (set-up time), minimizing this time and minimizing expenses caused by stoppages in the production lines.

The main consequences for this type production are traduced in:

  • Misuse caused by accumulated excess stock that isn’t sold, strain resources and extend the process lead time.
  • Delivery delays caused by productions that cannot adjust to the big quantities demanded by customers.
  • Damage in the quality of the stored products and increase in the storage space.

When the change of supplies is done quickly, the expenses of stoppages are drastically reduced, allowing the company a production in smaller batches and thus allowing:

 

  1. More flexibility to produce goods at the rate the customer demands. This way, bigger and changing demand can be attended to without maintaining big stocks.
  2. A production “set by the customer”, intern as well as extern, allowing short deadlines and faster delivery of goods.
  3. Productivity increase aroused by the set-up time reduction.
  4. Minimized WIP quantity, by the reduction of batch sizes.

The application of a SMED to a production line is structured in 4 differentiated stages:

  • Analysis of the initial situation (1st phase): Consists on identifying every preparation activity of the machines and tooling changes that influence the set-up time.
  • Clear splitting between internal set-up (standstill machinery) and external set-up (machinery in production) (2nd phase): this phase is about demonstrating the operations that can be performed with a functioning line.
  • Internal set-up conversion into external set-up (3rd phase): getting to this point, the objective centres in reducing the internal set-up, transforming to the maximum internal set-up operations to external.
  • Improves internal and external set-up’s procedures (4th phase): each one of the basic elements that influence in the operation must be analyzed. This analysis looks for simplification and standardization of the set-up activities.

LSMED’S main objectives are:

  • Reduction of the overall time (internal and external) needed to execute the format change.
  • Failure reduction bound to the set-up.
  • Stock reduction, of the finished product as well as the intermediate product.
  • Increase of the machine’s productive capacity (real).
  • Quality improvement.
  • Greater security (better conditions).
  • Greater “housekeeping” facilities (standardization of goods).
  • Reduction of production’s total lead time (process’ waits, batch’s waits and so on).
  • Greater production flexibility.
  • Greater staff motivation (lower rejection in production changeover).
  • Removal of “conceptual blockage” and new abilities’ development (continuous improvement).
  • Revolution on the production method.

Ultimately, the deployment of a SMED program allows us to improve:

  • Quality. To produce better and to produce more, with less faulty products, with less malfunctions.
  • Term. Productivity improves, which allows us to reduce the term the customer needs.
  • To produce at a expense that allows to generate more resources to the mill, with a lower level of existence and inventory.
  • Work conditions. Implies working better, with less accidents, less movements and useless transfers, greater cooperation and compromise, greater knowledge of the job function and so on, since the implantation technology is based on teamwork and allows to involve workers in the improvement process. Also, work safety improves significantly.

realidad aumentada mecanicaMaintenance Optimization

Nowadays, it’s essential for companies to invest in capacitation  to achieve goals and targets, and with this, to achieve the profitability and success they look forward to in the global market.

The maintenance department is one of the fields that companies must bet on all around the world, thus without this staff labour is always ready to fix any equipment failure the manufacturing processes would be interrupted over and over again, generating large and unexpected expenses for the companies.

It is important for employers not to look around in this field as the person who fixes machinery, but as a professional whose functions will guarantee that the manufacturing process is well done, in order and within the time agreed, to be able to offer a high-quality service that meets the customer’s expectations.

 

How to boost this department?

One of the key tools to count on qualified staff in the maintenance field is capacitation. This technique enables employees with the most updated knowledge global-market related, teaching them about the use of new technology as a base to achieve the company’s goals.

 

These capacitations have to be consistent and by hand with the changes that impact the market. The objectives the company pursues with this tool are:

 

  • Guarantee their tangible assets’ durability, so that the full benefit can be exploited in manufacturing processes.
  • Reduce inoperability caused by equipment malfunction in the multiple departments that are part of.
  • Improve machinery operation and productive gear used in the site, so that production can be faster.
  • Fulfill security regulations related to worker and environment security.

 

realidad aumentada comprobaciones criticas

Capacitations for the maintenance field

 

Capacitation must not be taken lightly: the employer must study the worker’s behaviour  and productivity level, so he can spot the flaws and, with the right formation, try to correct them.

This tool is far from being an expense for companies. Even though they have to spend some money to train their staff, it returns through practice. Practice of the acquired knowledge in them since they increase productivity indicators in their site, generating more profits within.

Some of the ideal expectations for the maintenance fields are those that reinforce their knowledge in new technology management applied to their workfield, such as:

 

  • Not only does the maintenance department fix equipment, but it knows how to manage their own human and material resources to run their functions.
  • Maintenance types that can be given in companies.
  • Maintenance processes and repair of different raw materials.
  • Plan, manual and numerical information interpretation about the equipment.
  • Detection and analysis of machines and systems’ mechanical failures.
  • Electric power generation, transportation and distribution.
  • Static machine’s use and repair.

It is important to know that goods that are part of a certain site’s manufacturing process system are prone to failure or damage caused by continued use or their past time. That’s why the maintenance department keeps this goods, making sure they’re well functioning.

 

With DiTi, companies will optimise these resources. Also, they will reinforce planification, analysis and control knowledge of the site’s different machinery. This will reduce inoperative time of a certain tool or equipment.

 


When companies are deploying an ERP system it is inevitable not to somehow affect all the operation and management field. Even though this is a great tool, we can’t keep out of sight this: is your staff ready to proceed with this technological tool? The key for the experience to be even better could be in an adequate capacitation.

Capacitation for ERP’S final users

An effective training and capacitation for your staff, who will be the acquired software’s final users, will be helpful for them to get involved in the process, to know the benefits it’ll bring within and reduce uncertainty. This will make them get involved in the project. It is important to consider that a management system goes further than being a software tool. It implies a project review and the best practices to each one of them.

This way your staff will need not only to use the software but to simplify their operative processes and look for the most effective and easiest way to accomplish them. This way, the margin of error will be smaller when saving information. This is why use of ERP and processes that involve their job position is important. They will be able to get the best out of the tool, and the investment the company is making could be more profitable.

Implementation of technology tools such as ERP Software is too helpful for companies. It allows them to align their proceedings and to be more efficient at doing them, making the best out of their resources to perform activities that bring value to the company. However, as in every single change, it isn’t easy, so constant capacitation for the right operation is vital. The outcome is a more competitive and productive company. In this sense, staff capacitation is key for the company to perceive and enjoy the benefits of an ERP.

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DiTi “Digital Training Innovation” is the easiest platform to use for smart design of Operational Processes and maintenance in real time through virtual, augmented and mixed reality.

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