Reducing the need for rework translates into lower operating costs, which is why it is worth implementing measures to address this issue. In this article we explain how an MES solution like Mapex can help you achieve your goal.
Rework has a very negative financial impact on industrial companies. Not only do they increase costs and add extra time to the manufacturing process, which can increase lead times, but they also consume labor and equipment, reducing the productivity of companies.
As we will see below, implementing efficient quality management systems, carrying out a good preventive maintenance plan, digitizing the necessary documentation in the plant, boosting connectivity and real-time communication among employees, and training personnel with the help of an MES solution such as Mapex are strategies that can help you reduce rework to a minimum.
What is rework in manufacturing and why does this occur?
Rework in the industrial environment occurs when materials, parts or products, which do not conform to the design specifications expected by customers, are reworked into products that meet the required standards and quality criteria.
There are a wide variety of hidden problems in factories that cause defects in production and, as a result, rework. These are just a few examples:
- Deficiencies in product planning or design.
- Poor quality of raw materials or components used in production.
- Equipment malfunction.
- Human error.
- Lack of trained personnel to perform specific tasks.
- Lack of adequate procedures to inspect and detect problems during the manufacturing process.
- Lack of clear and well-defined standards for production.
- Communication problems between the different departments or teams involved in the production process.
Identifying and addressing all these causes is key to reducing rework and increasing efficiency in the factory. Now we will see how an MES solution can help industrial companies achieve this goal.
5 ways to reduce rework with Mapex
1. Digitization of process documentation
Digitizing and centralizing plant information on an MES platform such as Mapex facilitates fast and accurate access to relevant specifications, procedures and records, significantly reducing the likelihood of human error due to misunderstandings or outdated data.
In addition, workflows are streamlined, enabling more effective process monitoring, early identification of problems and smoother collaboration between teams, leading to continuous improvement, minimizing errors and optimizing operational efficiency in the production chain.
On the contrary, if the company continues to use manual, paper-based documentation strategies, it is very likely to fall behind in the management of this information and become less competitive and efficient.
2. Connected and informed workers
Digitizing plant floor information is the first step in getting knowledge into the hands of factory workers whenever they need it.
In turn, keeping employees connected and informed in real time through an MES system is a powerful strategy for improving visibility, accuracy and responsiveness in the production environment, significantly reducing the incidence of rework by identifying, preventing and addressing problems in a more efficient and timely manner.
3. Management of operator training
There is no point in having connected workers and providing them with reliable information in real time if they are not sufficiently trained to make the most of this knowledge and perform their daily operations correctly.
In fact, knowing how to properly manage the level of operator training is one of the major challenges facing many industrial companies today in order to reduce rework.
As we explain in this article, Mapex can help you tackle this task. With our MES system you will be able to implement the ILUO system in your company, and automatically detect and determine the levels of professionalism required for your workers to perform which processes and/or manipulate which machines.
4. Promotion of preventive maintenance
Not everything has to do with human error; in an industrial environment, equipment also breaks down. For this reason, in order to avoid reprocesses linked to machinery failures, many organizations opt to implement a CMMS such as MapexMM.
Thanks to this software, manufacturers are able to avoid future problems related to equipment by performing proper preventive maintenance and extending the useful life of their equipment as much as possible.
5. Culture of continuous improvement in quality management
Effective quality management practices are another very useful strategy to keep rework under control.
An MES provides real-time tracking of the main quality KPIs and also has very useful functionalities to quickly identify and address deviations in production, prevent non-conformities and continuously improve processes as well as the level of customer satisfaction.
For more information, you can contact us through this form. Remember that you can request a demonstration of our MES solution or of any of the modules you are interested in.
