If you have been through our last article mentioned under title “A quick look into the history of manufacturing automation” (if not, you van visit http://aagengg.com/industry-news/look-history-manufacturing-automation/ ) on how manufacturing sector has turned from running manual processes to automated, is it time for it to turn into paperless manufacturing industry?
Manufacturers are moving towards automation of the plant mainly to automate the plant operations, to reduce manual labor, cost, cycle time and errors. The production process has evolved into the more complex process now. Production plants mainly run on technological equipment with minimal human intervention.
In spite of all these progress, what effective manufacturers fail to notice is that they continue to use paper-based manufacturing systems.
Paperwork is still done for production forms, QC forms, Packing Lists, WIP details, Indents, Purchase requisitions and so on, the list basically encompasses the entire operation of the plant.
It raises a question on so-called ‘Automated plant.’ Are these plants automated in the true sense? Then why millions are spent on equipment when the process will only be partially automated, partially integrated and partially efficient?
The fact is even if an organization claims to utilize highly advanced equipment for their processes but still use paper-based documents as the sole communication mode, it cannot be considered an automated and integrated production unit.
The reason I am stating the harsh statement is that paper-based systems hamper the ability to make real-time, informed and accurate decisions. Even the chances of a manual error in reporting or calculation are inherent in such a system. Mentioned below are disadvantages of using paper as the only mode of communication.
Drawbacks of using Paper documents as sole media of communication
- Lack of document control: Paper use makes it very difficult to have a complete visibility of the document status together.
- Inefficient CAPA management: It is not only difficult but even time consuming to determine the source of the error from a pile of documents The case gets worse when issues arise at customer end and old documents have to be fished out of files.
- Lack of preventive actions: It is simply impossible because an issue that occurs today might be reported tomorrow and reviewed the day after.
- Inaccurate process metrics: Process metrics get reported inaccurately and insufficiently. It raises the difficulty for engineers and consumes lots of the time, effort and cost.
- Increase cost: The poor quality, erroneous documentation, faulty requisitions, higher percentage rejections, higher maintenance expenditure and cost of time spent by employees working with the paper-based system increase cost subsequently.
- Environmental degradation: Not to mention the environmental issues caused due to manufacturing and recycling of paper is too high.
So, how can a plant become fully automated in the true sense?
IT system can integrate the entire manufacturing process from beginning to end. A well-designed software application can replace paper formats completely, right from material sourcing to finished goods dispatch. Every activity in the process can be represented by the system and this allows for the much-needed visibility and helps integrate the activities. It helps streamline the entire operation and ensure better coordination, with clearly defined ownership for both activities and material.
Most importantly only a qualified person can make the required changes thus reducing the chances of error.
For a plant to be fully automated, an application is required that can include equipment as a part of the process. Integrate communication and action, and enables proactive management with end-to-end visibility.
Such kind of automation can only be achieved with a paperless system.
AAG Engineering Technologies has high efficiency in converting your plant into fully automated one. Enquire more about it at sales@aagengg.com or have a look at all our services at www.aagengg.com.
