Learn Archive - Selfbits GmbH

Data security

Hanno Schifferdecker — Mon, 16 Jun 2025 15:30:07 +0000

Data security

Data security encompasses every measure aimed at protecting all types of company-owned data. Besides shielding information from unauthorised access, it also preserves data integrity against manipulation and technical failure. In order to run business processes smoothly, data security must additionally guarantee the permanent availability of the data.

Image: Sample illustration

Protect your Business - Secure your data!

Cybercrime, cyber-defence, cyber-analytics – there is no shortage of buzz-words in the realm of IT security. All of them refer to the online world, yet none pinpoints a single specific issue. Taken together, however, these lofty terms highlight a trend that deserves our utmost attention!
Today, hacking attacks are a daily occurrence across every industry. The growing number of mobile, networked systems has two consequences. First, companies face a rising need to safeguard data: they must protect their systems from unwanted access, ensure high data quality and at the same time guarantee continuous availability. Only when these three components are secured can data be transformed into information and, through analysis, be put to valuable use. Second, the losses caused by cyber-crime are climbing sharply. According to Germany’s Federal Criminal Police Office, cyber-attacks alone racked up damages of more than €203 billion per year in Germany.
Long story short – data security is a matter for top management! Data security covers every measure whose goal is to secure a company’s data. The decisive factor when implementing security measures is the state the data are in at the moment of protection:

Stored data
Data being processed
Data in transit

Depending on that state, different protective options exist. Although no measure can provide 100 percent security, IT security can be improved continuously and systematically. Every facet of data security must be considered if the protection is to be as comprehensive as possible. In the era of the Fourth Industrial Revolution – better known as Industry 4.0 – data security is moving ever more into focus. From automated machine-data collection on the shop floor to the fully digitalised smart factory, vastly more data circulate today than in past generations.

Five Important Facets of Data Security

Every facet contributes a building block to data security within the company. If one facet is ignored or left without appropriate measures, the other safeguards also suffer. Only a complete view of all facets provides a solid basis for building further protective mechanisms.

Due to process-related, physical, and structural conditions, transport is often unavoidable and thus frequently falls into the category of necessary value-enabling waste. Nonetheless, the goal should be to reduce transport as much as possible and to keep walking and transport distances as short as possible.

1. Confidentiality

Stored or transmitted data are protected against unauthorised access. That means only authorised persons may reach stored data. The same care must be taken during transmission so that no one can intercept them. Symmetric or asymmetric encryption methods are generally used to ensure this facet.

2. Integrity

Integrity means maintaining the completeness and high quality of the data. Suitable measures protect them against unwanted change and manipulation. Safeguarding data against loss due to technical failure is also part of this facet. Access controls log entry to the data and make changes traceable. Regular data backups further reduce the risk of data loss.

3. Availability

If access rights exist for certain data, those data should be fully retrievable and usable at any time. That minimises the risk of system downtime. Synchronised storage solutions or cloud use are typical ways of achieving this.

4. Transparency

Ensuring transparency here means that the origin of the data and the way they are used can be proven. Clear assignment and legally compliant handling are guaranteed, for example, by logging access.

5. Authenticity

Proof of the data’s origin ensures authenticity. Determining the identity of the data is also an aspect of integrity. If the origin can be determined, verification can rule out the possibility of deception of a recipient. In digital data traffic, identity verification is often carried out using encryption, such as a public key infrastructure. This ensures that data arrives unchanged at the correct recipient when retrieved or sent.

Preserving data security in all its facets must be anchored throughout the entire corporate structure. To exploit all the opportunities offered by operational data collection, analysed data should be used not only in shop-floor management but also in corporate-goal planning. The cycle between data collection and calculation of target data also harbours optimisation potential for leaner processes.

Goal reached, job done?!

If only it were that simple. Digital transformation is advancing rapidly, constantly opening up new possibilities – alongside efficient innovations, new avenues for unauthorised access arise as well. The goals of data security therefore have to be pursued continuously. Identifying and assessing threats is best handled through recurring, dynamic processes viewed from an attacker-centric perspective.

First, define objectives that must be met for the sake of security. Next, develop attack scenarios to uncover possible weaknesses in the system. After a simulated attack, weak points can be analysed and counter-measures initiated. This process runs at regular intervals, ensuring ongoing optimisation.

Once planning and a suitable strategy are in place, only implementation remains. Outstanding examples worldwide show how crucial the right approach is during implementation, not just for cutting costs but also for generating value.

Five Fundamental Steps to Data Security in the Company

1. Communication

The most important component! Employees must be sensitised to data security. They need to understand why certain processes are necessary and be aware of the consequences of lacking data security. Only then can the measures be implemented correctly. Once understanding has been built, training sessions should be held and competences developed.

2. Device Status

Every device connected to a network should be checked for its security status and data. Regular status reviews and backups raise security with simple means.

3. Updates

The company’s security software must, of course, always be up to date. Carrying out regular updates must become a fixed process.

4. Transparency

Work processes should be clearly defined so that access and authorisation rights can be granted accordingly. Only persons who actually need access to certain data to perform a task receive it.

5. Encryption

Any decrypted access to corporate data should occur only for the duration of access. Company personnel should naturally secure all devices in the network with strong passwords. When away from the workplace, all accesses must be blocked.

Conclusion

Combining information gathering and employee awareness forms a solid foundation for data security. Additional security standards can be built on that and continually refined.

Instead of leaning on the buzz-words mentioned at the outset, it pays to engage with the practical measures required for data security.

Der Beitrag Data security erschien zuerst auf Selfbits GmbH.

Andon

Hanno Schifferdecker — Mon, 16 Jun 2025 14:59:49 +0000

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Andon

Andon is a visual management method and part of the Toyota Production System. In Japanese, the term “Andon” means (paper) lamp. With classic traffic lights and monitors (“boards”) in production, the Andon method forms a visual control system for the production status.

Image: Example of an Andon board

What is Andon?

The Andon method encompasses both the visualization of the status of a machine or process and the ability for employees to change this status.

The original form of Andon can now be found in many places, even outside of production. They are ubiquitous not only on machines in manufacturing, but also on self-service checkouts and deposit machines: simple stacked traffic lights with the colors red, yellow, and green that clearly indicate the current status.

Warnings, errors, and malfunctions can be viewed remotely by staff, and the location of the malfunction is immediately clear. The self-explanatory color coding also clearly indicates the problem category as reaching a warning or intervention limit.

In addition to the ubiquitous traffic light lamps, other forms of the Andon method have also been developed. Today, there are Andon boards, which can range from simple counters to elaborate dashboards, and various devices for workers to report status, known as Andon cords.

Andon boards

The Andon board is a visual control device used in manufacturing. In its simplest form, it can display only the current number of units or the status of the line. More advanced versions display any status information about the respective production line or manufacturing process. As part of the Selfbits Manufacturing Suite, our customers use the display for OEE, current production progress, and current production figures and quality data.
The data for the display is collected automatically via machine data collection or manually by employees via production data collection and aggregated and displayed in near real time.

Andon-Cord

The Andon cord is another tool for recording the current status. As the name suggests, there may be pull cords on a production line, for example, that enable an employee to report an error or difficulty so that they can receive assistance. Similarly, an Andon cord can also be designed as an emergency stop switch, in the form of a pull cord or an actual switch. This enables the employee to initiate a conveyor or plant shutdown in the event of problems. Here, the use of Andon cords also directly records the location of the problem through the report itself. This reduces the need for inquiries and enables a quick response.

Summary

Features

Visualization of the operating status of a machine/production line
Reporting a discrepancy in order to remedy the situation
Stop the production plant in case of danger and stop the further flow of substandard products.

Advantages

Improved transparency – Immediate availability of information increases transparency
Improved productivity – With immediate visibility of problems, they can be resolved more quickly.
Increased flexibility – With Andon, workers can take on more responsibility because the current status is transparent.
Increased plant availability – With Andon, faults can be identified and rectified more quickly.
Save time and money – Andon is a simple method for exchanging information on the shop floor.

Der Beitrag Andon erschien zuerst auf Selfbits GmbH.

Availability in OEE calculation

Hanno Schifferdecker — Mon, 16 Jun 2025 14:55:25 +0000

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Availability in OEE calculation

Availability is one of the three factors used to calculate OEE. Below, we show how it is defined and calculated.

Image: Sample illustration

Introduction

Availability is a percentage indicator. It describes the extent to which a machine’s capacity is used for value-adding functions in relation to its planned availability. It is calculated as the ratio of the actual production time to the planned busy time.

The planned operating time results from the total reference period (e.g., one calendar week) minus non-production periods (e.g., weekends) and scheduled downtimes (e.g., routine cleaning and machine maintenance).
To determine the main operating time, actual stoppages, breakdown-related interruptions and the actual setup time are deducted from the planned operating time; the main operating time is therefore an actual time, i.e., one measured in reality, which makes it crucial for an accurate OEE calculation to record this time as precisely and immediately as possible. As mentioned above, availability is obtained as a percentage by dividing the main operating time by the planned operating time.

Availability =

Main Operating Time

Planned Operating Time

From this formula it follows that availability must always refer to a specific time interval. It is generated periodically and on demand. Values range from 0 % up to a maximum of 100 %. The larger the number—meaning the higher the utilisation of the machine relative to the planned time—the better. In the context of OEE, availability is also called the utilisation rate and forms the third factor, alongside performance and quality rate, in the equation. Availability, like the OEE derived from it, is relevant for shop-floor operators, plant management and executive leadership, because OEE is widely accepted as the benchmark and key indicator of an industrial facility’s productivity.

Source: VDMA 66412-1 : 2009-10

Der Beitrag Availability in OEE calculation erschien zuerst auf Selfbits GmbH.

Poka Yoke

Hanno Schifferdecker — Mon, 16 Jun 2025 14:40:48 +0000

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Poka Yoke

Avoid “unfortunate mistakes” by using Poka Yoke to uncover errors and reduce opportunities for error.

Image: Sample illustration

Introduction

Description:

The Japanese term Poka Yoke (meaning “avoiding unfortunate mistakes”) can actually be defined simply as “avoiding mistakes”. The fundamental goal is a zero-error state. At the same time, however, it is recognized that no system and no human being is able to completely avoid unintentional errors. They are part of every production and process. Poka Yoke therefore attempts to reduce or completely avoid errors with mostly simple but effective systems and to reduce the impact of errors in the production process on the end product.

Shigeo Shingo is considered the inventor of the principle and the linguistic origin is derived from Go and Shogi (a Japanese variant of chess): In these, poka denotes a wrong move. In a broader sense, it means “stupid mistake, blunder”. Yoke comes from the verb yokeru, which means “to avoid”.

As Poka Yoke was developed as part of the Toyota Production System, it has its origins on the store floor. However, the principles also apply in the office, warehouse and service sector, as the examples below clearly show.

Advantages

Processes in which fewer errors occur increase quality, but also have a significant impact on productivity. As the quality factor increases, the OEE naturally also increases. Throughput times can often be reduced with less rework and simpler processes. Of course, there are also cost factors.

Application and basic rules

The application of Poka Yoke is very simple: trace errors back to their sources and check how you can prevent the error from ever occurring again.

The six basic rules help with the application and can be guidelines for a suitable solution

Try not to spend money
Simpler is better
Do not make the use of Poka Yoke optional
Do not confuse measuring instruments with errors
Reduce decisions

Procedure

First identify the errors that occur in your production
Use the Pareto principle to decide which you should work on first
Find out the process step in which the observed error occurs
If your processes are not standardized, this should be the first step. Because designing a Poka Yoke for a non-repetitive process is a waste of time.
Think about what needs to be done to ensure that this error never occurs. This could be a change to the component, a change to the device or machine or other simple support for the workers at the workplace.

Examples from production

Poka Yoke in Part Design

Chamfer on a corner of a component to enable only one correct placement or connection (e.g. also SIM cards)

Staggered, asymmetrical placement of drill holes to create only one mounting option

Poka Yoke in the design of devices and machines

Position sensors only allow a pressing process to start when the component is inserted correctly

Poka Yoke in process design

Query of eye color in forms for customer service employees to ensure eye contact with the customer

Examples from Everyday Life

Car key, USB type C and Lightning cable: They can be used on both sides and therefore cannot be used incorrectly.
USB type A cables: they can only be plugged in in one orientation, often to the frustration of users
Overflow drains in washbasins and bathtubs: They prevent the bathroom from flooding
Cash machines: They first return the card and then dispense the cash withdrawn. This means that the card is less likely to be forgotten.
Dispensing nozzles: They release their locking mechanism as soon as the tank is full, thus preventing overfilling and fuel leakage

Der Beitrag Poka Yoke erschien zuerst auf Selfbits GmbH.

Value Stream Mapping

Oliver Kuppler — Mon, 16 Jun 2025 14:36:41 +0000

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Value Stream Mapping

“Wherever there is a product for a customer, there is also a value stream.
The challenge lies in seeing it.”

Mike Rother, John Shook – Learning to See

Introduction

Value Stream Mapping (VSM) is a method for visualising manufacturing processes—specifically, their entire value stream — so they can be analysed and optimised. All activities, both value-adding and non-value-adding, that are necessary for the manufacture of a product are recorded. Together with the flow of materials and information, as well as process and warehouse data, this creates a holistic picture of production.

As the first phase of value-stream management, VSM captures the current state, uncovers non-value-adding processes and exposes waste. Value Stream Design then sketches a future state that shortens waiting times and eliminates unnecessary work, aiming for a flow with short lead time and a high share of value creation. Finally, Value Stream Planning organises and executes the transition from the current to the future state.

In their standard work Learning to See: Value-Stream Mapping to Add Value and Eliminate Muda (Amazon link), Mike Rother and John Shook describe two streams: the manufacturing stream, which carries raw material to the finished product, and the development stream, which takes the product concept to production start-up. Both can be examined with VSM, but the focus here is on the manufacturing stream—“dock to dock.” During the analysis this stream is traced backwards from customer demand to raw material.

Method and Procedure

1. “Segmenting production”: selecting a product or product family

Before mapping begins, the right “altitude” must be chosen. Examining every product family across the whole enterprise is neither practical nor useful. A good starting point is to pick one product or family with prioritisation methods. An ABC/XYZ analysis works well for a single product; for grouping products into a family, use their final production steps. A SIPOC diagram then sets clear start and stop events—typically order receipt as the start and shipment as the stop—so the analysis has precise boundaries.

2. Determining the customer takt

Next, calculate the customer takt for the chosen product or family from average demand and available production time.

Example assumptions:

Annual demand: 12 000 units
Production capacity: 48 weeks (5 days/week, two 8-hour shifts → 28 800 s per shift)

Calculation:

Output per shift = daily demand (= 12 000 / 50 / 5 = 48 units) / 2 shifts = 24 units/shift
Customer takt = 28 800 s / 24 units = 1 200 s per unit (20 min)

The process therefore must produce one unit every 1 200 seconds to meet average demand; slower output fails to satisfy the customer.

3. Visualising the process diagram: sample value-stream map

The first step is to visualize the entire value stream. Observation takes place from the goods issue or from the customer back to the raw material.

3.1 Capturing material and information flow

Distinguish push from pull flows.
Include incoming-goods checks and quality inspections.
Document information flows—how orders arrive, are released to production and transmitted (type, frequency, approvals).

3.2 Defining process-data boxes and times

Record all process-relevant data (cycle time, change-over time, scrap rate, yield, machine availability, etc.); Define lead times and the shares of value-adding vs. non-value-adding time; Derive indicators for assessing process efficiency.

3.3 Validating the current state

All participants review the map to confirm every interface as well as material and information flows.

4. Identifying potentials and defining the future state

Once the map has been completed and validated, it serves to reveal waste wherever it occurs—often made obvious by the visualisation itself. Together with the process owners, a new future process is defined in the Value Stream Design phase so the customer takt can be met more effectively.

Der Beitrag Value Stream Mapping erschien zuerst auf Selfbits GmbH.

What is an ERP System?

Hanno Schifferdecker — Mon, 16 Jun 2025 14:21:47 +0000

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What is an ERP System?

Image: Sample illustration

Importance of ERP Systems

ERP systems have evolved from a nice-to-have into a decisive competitive factor. Among small companies with 10–49 employees, only about one in five uses one; in medium-sized firms (50–249 employees) the figure already exceeds half. Large enterprises with 250 or more staff now regard ERP solutions as standard, with adoption approaching three quarters. Manufacturing leads the way: across all size classes, usage rates there run roughly 20 percentage points above the average, so nearly 60 % of industrial firms already deploy an ERP system versus just under 30 % in the economy as a whole. Company size and production depth therefore raise the need for integrated enterprise software significantly.

What Are ERP Systems?

ERP stands for Enterprise Resource Planning. An ERP system is software designed to deploy a company’s resources effectively and efficiently. These resources include

raw materials
capital
personnel
operating equipment (e.g. machines, tools, ICT)

The system helps plan these resources, both operationally and strategically, so that—just as in logistics—they are available in the right quantity, at the right place, at the right time. Extending this idea, the six-R rule adds the right quality, the right cost and the right information. In this way an efficient value-creation process and smooth operations can be maintained.

The origin and core task of ERP is material requirements planning, whose purpose is to procure the materials needed to manufacture a product in accordance with the six-R rule. Key performance targets are therefore:

high quality and high productivity
high supply security and low capital tie-up
complexity reduction and flexibility
high continuity and short lead time

Excursus: Material Requirements Planning

Material requirements planning usually involves three steps:

considering on-hand stock ready for production
identifying additional net demand: required quantity minus current inventory
planning production and/or purchases of parts and raw materials to cover the net demand

An integrated ERP system, for example, would create a matching production order after a purchase in the company’s own shop (make-to-order) or trigger picking for shipping if the item is in stock.

If production lowers inventory below the minimum level, the system automatically generates a purchase proposal so new raw materials or parts can be sourced.

Because the ERP system makes data and information readily available, regular orders can also be scheduled to cover average demand. Advanced users may, depending on the part (e.g. based on an ABC/XYZ analysis), factor in stochastic distribution and plan requirement by service level (e.g. 80 % availability). Companies may also carry materials with a use-by date; ERP supports this as well.

Although these issues arise first in material planning, they affect every resource in the enterprise, making an ERP system an indispensable tool once a business reaches a certain size.

Main Tasks and Functional Areas

Beyond material requirements planning, ERP systems handle many other tasks, though materials management remains their core. Numerous company processes can be mapped and controlled in the ERP. Classic fields include:

materials management (procurement, inventory, planning)
customer-relationship management (CRM)
purchasing
sales forecasting and distribution
(rough-cut) production planning and control
- bills of materials
- routings
demand planning
finance and accounting
merchandise management
controlling
human resources
business intelligence and analytics
product data management
document management

ERP systems also cover areas such as

research and development
sales and marketing
project management
operational data collection
service processing
group consolidation
business-process management

Key Features, Decision Factors and Distinction from Other Software

Hundreds of ERP systems exist, often offered in two variants by the same vendor: on-premise or cloud. Each has pros and cons driven by the effort of self-hosting (on-premise) versus reliance on a provider (cloud). Details are discussed in our white paper.

Besides the on-site/cloud choice, other criteria help select the right ERP:

industry focus
company size
functional scope offered
technologies used

Some ERP systems are universal, covering many industries and typical sector processes—either built-in, modularly or via partner add-ons. Others specialise in one or very few sectors and address their challenges more precisely.

Company size is another factor: larger firms often gain from cloud ERP because it scales easily and demands less client computing power—thin or zero clients that merely display a web interface can suffice.

Functional needs vary. One example is support for an e-commerce system running on the company’s website, accessible to customers stored in the ERP’s CRM module, with orders posting straight into ERP—something not all solutions provide.

Cost is critical too: purchase price, total cost of ownership (licences, operations, hosting) and total cost of change (implementation, maintenance, adaptation) all matter. Though hard to quantify, lock-in costs should also be weighed.

Best-of-Breed Strategy

Distinguishing ERP from other software can differ. Especially in smaller firms, separate tools—for CRM, MES or HR, for instance—may be chosen and linked only via interfaces. Numerous providers such as Salesforce, Zoho, Pipedrive and HubSpot have emerged. This approach is called a best-of-breed strategy.

Here, vendors specialise in one solution (e.g. HubSpot for CRM, Selfbits for MES) and often surpass universal ERP providers in their niche. A system integrator then connects the standalone solutions, sometimes through simple scheduled table synchronisations or via middleware that keeps data aligned. This Software-as-a-Service model charges only for actual users and eliminates deployment or hosting effort aside from training.

Advantages and Disadvantages

The benefits of an ERP system are clear: it is a holistic tool for managing, controlling and planning virtually all company resources. From a certain size upward, using ERP becomes almost unavoidable. In some sectors—especially services—certain ERP modules may be unnecessary, and standalone solutions with interfaces can model specific functions better than universal ERPs.

Additional advantages include

simpler reporting
data security
defined workflows
competitiveness
automation
standardised, more transparent processes
central data storage

Drawbacks lie in the high financial and time investment for implementation, the effort to maintain master data and configure the software so it yields lasting benefit, and the lock-in effect: once chosen, switching is difficult and costly, tying the firm to its vendor’s problems, strategy shifts and pricing. Further disadvantages explain why adoption among small companies is low:

high implementation and maintenance costs (varying by licence model)
necessary adjustment of company processes or the software
organisational change (training, process redesign)
discipline required to ensure lasting efficiency gains
not always user-friendly
implementation takes a long time (> 6 months)
lock-in effect

Market Overview

Vendors and Their Products

SAP S/4Hana / Business One
Microsoft Dynamics 365 Business Control
SAGE 100
Infor M3
Oracle NetSuite / Cloud ERP
Workday
Deltra Business Software
Scopevisio
Lxebizz
myfactory
Abas ERP
Weclapp
Actindo
DATEV
ProALPHA Business Solutions
Asseco Solutions
Gewatec
Embedded projects
Xentral ERP
PACS Performer
Epicor ERP
Myfactory
TOPIX ERP

Der Beitrag What is an ERP System? erschien zuerst auf Selfbits GmbH.

Value Stream Management

Oliver Kuppler — Mon, 16 Jun 2025 13:58:31 +0000

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Value Stream Management

Value stream management is the capture, control and planning of production and material flows in manufacturing — together with the associated flows of information.

Image: Sample illustration

Introduction

Value stream management breaks down into three consecutive disciplines: value stream mapping, value stream design, and value stream planning. Run in sequence, they serve as tools for shortening lead times and optimising production. The standard work on the topic—Learning to See: Value-Stream Mapping to Add Value and Eliminate Muda by Mike Rother and John Shook—walks through a complete improvement cycle and describes value stream management in depth.

Value Stream Mapping (VSM), constitutes the first part of value stream management. Its aim is to record the current state and identify non-value-adding processes and waste. After the analysis, the value-stream design phase drafts a future state that shortens waiting times and eliminates non-value-adding activities. The objective is to create a value-stream flow with short lead times and a high proportion of value creation. In the final phase, value-stream planning, the transition from the current state to the future state is organised and carried out.

Objectives

A shared, easily understandable language for discussing production and the production process
A clear view of the relationship and interaction between information flow and material flow
Insight into more than just the “process level” by revealing the underlying flow
Identification of the root causes of waste
Prevention of sub-optimisation that targets obvious waste without a holistic perspective
A sound basis for an implementation plan
Requires nothing more than pencil and paper

Advantages

Creates a model of the material and information flows within a value stream
Improves process control in production
Identifies non-value-adding processes
Provides a big-picture, holistic view of the process from goods receipt to goods dispatch
Visualisation highlights improvement potential
Maps information and material flows, enabling optimisation through the elimination of waste

Der Beitrag Value Stream Management erschien zuerst auf Selfbits GmbH.

Value Stream Design in Manufacturing

Oliver Kuppler — Mon, 16 Jun 2025 13:26:50 +0000

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Value Stream Design in Manufacturing

Value stream design aims to eliminate the causes of waste uncovered during the value stream analysis by developing a future-state process. The manufacturing steps identified are linked by continuous flow production or supermarket pull systems, so each process makes only what the next process needs, precisely when it needs it.

Image: Sample illustration

Introduction

Value stream design is the second step of value-stream management. Based on the current-state map, a “future-state” is drafted. The goal is to create an improved, customer-oriented flow of materials and information. The previous step, value stream mapping, laid the groundwork by tracing production backward from the customer (internal and external) to the supplier and recording the flows in a value-stream diagram.

In short, value stream design sketches how today’s production should work tomorrow, eliminating non-value-adding activities. The activity plan created during value stream mapping serves as the starting point.

Procedure

When designing the value stream, follow these seven guiding principles:

Assemble to the takt time
Develop continuous flow wherever possible
Use supermarket pull systems for production control
Plan production at only one point in the value stream (the pacemaker process)
Level the mix and volume of products at the pacemaker process over the available time
Create an “initial pull” by releasing and withdrawing small, even work batches at the pacemaker process
Develop the upstream processes so they can “make every part every day.”

Characteristics of Value Stream Design

One of the main goals is to link all processes in the value stream so they flow as a single stream, driven primarily by customer pull. Tight coupling of processes shortens lead time while reducing inventory, defects, and scrap. Control shifts from managing individual processes to steering an entire, efficient, customer-oriented value stream.

Objectives of Value Stream Design

The objective of value stream design is to work on the overall picture and not just on individual manufacturing processes. The focus is on the holistic optimization of production – “from ramp to ramp” and then on to suppliers and customers.

The focus is on the big picture, not isolated manufacturing steps—optimizing production holistically “from dock to dock,” and ultimately extending to suppliers and customers.

Reduce inventories
Shorten lead times
Improve quality
Increase delivery reliability to the customer

Der Beitrag Value Stream Design in Manufacturing erschien zuerst auf Selfbits GmbH.

What is MTConnect?

Hanno Schifferdecker — Mon, 16 Jun 2025 13:15:37 +0000

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What is MTConnect?

Definition of MTConnect

MTConnect is an open communication standard used in the manufacturing industry to collect, transmit, and analyze machine data. It offers a standardized method for capturing and transmitting data from various types of manufacturing machines and equipment, regardless of manufacturer or model.

The operation of MTConnect is based on a simple concept: Machines and systems that are compatible with MTConnect are equipped with sensors and control systems that continuously gather data about the machine’s condition, process parameters, operational status, and other relevant information. This data is then encoded in a standardized format and transmitted in real time over a network connection.

Mode of operation

MTConnect is an open communication standard that provides a standardized method for capturing, transmitting, and analyzing machine data in the manufacturing industry. The technical functionality of MTConnect is based on a hierarchical data model and a simple XML-based communication protocol.

The functionality primarily encompasses three main components:

1. Data Sources: Data sources are the machines and devices in a manufacturing facility that are equipped with sensors and control systems to collect various data such as operational states, production parameters, tool conditions, etc. These continuously transmit data to an agent.

2. Agents: Agents are software components that receive data from one or more data sources and store it temporarily. Upon a client’s request, this data is transmitted to the client in the MTConnect format. Optionally, adapters can be used to convert raw data from data sources into a format readable by agents.

3. Clients: Clients are the software applications or systems that ultimately receive, process, and utilize the machine data. These can include monitoring and diagnostic systems, data analysis applications, Manufacturing Execution Systems (MES), or Enterprise Resource Planning (ERP) systems.

MTConnect defines a standardized data model that describes the various types of machine data and their structure. The collected data is structured in XML files, where each data field has a unique name and an associated value. This allows for a uniform interpretation and processing of the data by different software applications, regardless of the specific type of machine or manufacturer. Clients retrieve the data relevant to them at regular intervals from the agents. The data transmission occurs in real time via standardized network protocols such as Ethernet or WLAN.

Relevance

The significance of MTConnect in the manufacturing industry lies primarily in its ability to standardize and simplify the capture, transmission, and analysis of machine data. By implementing MTConnect, manufacturing companies can realize a variety of benefits:

1. Interoperability: MTConnect enables seamless integration of machines and devices from different manufacturers, regardless of their specific control technology or communication protocols. This allows manufacturing companies to use their existing machines more efficiently and to easily integrate new equipment into their production environment.

2. Real-time Monitoring: The communication standard allows for the continuous monitoring of machine and production data in real time. This enables operators to accurately track the condition of their facilities, detect potential problems early, and take immediate corrective or optimization actions.

3. Data Analysis and Optimization: By capturing extensive data on machine operation, manufacturing companies can conduct advanced data analyses to identify trends, recognize bottlenecks, and find optimization opportunities. This can help increase productivity, improve efficiency, and optimize the overall performance of manufacturing facilities.

4. Transparency and Traceability: MTConnect allows for comprehensive tracking of production data and process parameters. This contributes to improved quality assurance, ensures compliance with quality standards, and facilitates the traceability of products.

Applications of MTConnect

Numerous machine and control manufacturers offer interfaces for MTConnect, such as

Allen-Bradley
Balluff
Blum Novotest
ControlLogix
DMG Mori Seiki
Doosan
Fagor
Fanuc
GFAgieCharmilles
Haas

Heidenhain
Makerbot
Makino
Mazak
Mitsubishi Electric
Moxa
Mitutoyo

NUM
Okuma
ROS-Industrial
Siemens
Sodick
Toyo

Particularly in the segment of milling, turning, and other machine tools, the availability of MTConnect interfaces is widespread. Moreover, MTConnect has found its greatest adoption in the North American market, where the development of the standard had originated.

Source: MTConnect Institute

Der Beitrag What is MTConnect? erschien zuerst auf Selfbits GmbH.

What is an MES system?

Hanno Schifferdecker — Mon, 16 Jun 2025 13:08:03 +0000

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What is an MES system?

Definition

An MES (Manufacturing Execution System) is a software system used in the manufacturing industry to monitor, control, and optimize production in real-time. It helps ensure efficiency, quality, and compliance in the manufacturing process, improve production performance, increase product quality, and reduce costs.

MES support processes at the production line level and serve as an interface between ERP systems at the enterprise level and the machines and equipment at the manufacturing level.
The functions and tasks of MES-sytems are definied in the VDI5600 guideline.

The role of MES in industrial manufacturing

At the enterprise level, ERP systems are used to manage various business functions such as finance, procurement, sales, and human resources. These systems provide a comprehensive overview of the entire company’s activity and assist in resource planning, order processing, and strategic decision-making.

On the other hand, MES operate at the production line level. They receive orders to be executed in real-time and break them down into operations. Based on this, MES allow for the resource-optimal planning of the operations required for manufacturing on the available machines, taking into account various constraints.

At the production level, the manufacturing machines and equipment on the shop floor transmit all relevant data for production control, such as production of good parts, scrap, as well as the start and end of disruptions and other downtimes, to the MES in real-time. This increases transparency in the manufacturing process and allows for continuous monitoring of production progress.

Building upon the machine data, MES enable the analysis of production processes and provide performance parameters such as availability, produced quantities, quality losses, OEE, and more. Based on these metrics, weaknesses and issues can be identified and addressed accordingly.

What benefits does an MES offer?

A Manufacturing Execution System offers a variety of benefits for the manufacturing industry, including:

Real-time monitoring: MES enables real-time monitoring of production processes and swift response to issues or deviations.
Increased efficiency: MES can help boost production efficiency by automating processes and simplifying performance monitoring.
Improved quality control: MES facilitate the monitoring and documentation of quality control processes, ensuring higher product quality.
Data collection: MES collect and store extensive production data, which can be used for analysis and decision-making.
Data analysis: MES calculate various KPIs and provide different visualizations to present important information to different user groups at a glance.
Cost savings: MES can help save costs by optimizing workflows and streamlining production monitoring.
Integration with other systems: MES can often be integrated with other systems, such as ERP or SCADA, to provide comprehensive support for manufacturing processes.
Increased transparency: MES provide real-time information on the progress of all orders, enabling quick and reliable fulfillment of customer information needs.

Overall, a well-implemented MES can play a crucial role in improving production performance, quality control, and efficiency enhancement.

Der Beitrag What is an MES system? erschien zuerst auf Selfbits GmbH.