7 Reasons Manufacturers Are Choosing Manufacturing Control Software

With the advent of Industry 4.0, manufacturers are increasingly investing in the latest advanced technology in order to achieve their smart factory ambitions. A game changer in this department is manufacturing control software, which is having a major impact on manufacturing process as well as easing the manufacturer’s workload.

Are you considering implementing control software in your business but unsure of the applications? Or have you just heard about control software and want to learn more?

We explore the top 7 reasons why manufacturers are choosing manufacturing control software below:

1.  Improves Planning Process
While the product is being manufactured, the materials used are tracked to allow you to order materials in advance instead of realising too late, creating a smart manufacturing process.

2. Reduces Manufacturing Cycle Time
Through the use of manufacturing control software, manufacturers have greater visibility and control of the order process from step one right through to completion and the final shipment. By having all steps in the process automated, scheduled and materials in full supply, there is less chance for scenarios to crop up that would delay the manufacturing process, hence reducing the manufacturing cycle time.

3. Improves Product Quality
Every part that is produced is done so according to a formal build plan that comprises of a set of digital work instructions at each stage of the manufacturing process – by sticking to this plan, optimum quality is ensured.

4. Reduces Lead Times
Put an end to a cycle of poor organisation – how many instances of production delays have there been as result of parts not being available at the assembling station? Manufacturing control software tracks parts automatically throughout the manufacturing process.

5. Minimises Waste
Keeping waste to a minimum is a common challenge for project managers. By controlling production, manufacturing control software can identify occurrences of waste and implement a strategy to reduce the amount of waste produced. As well as this, the software can also keep track of machine downtime and maintenance, which ensure a steady flow of output is achieved, and eliminates any areas of wasted productivity.

6. Reduces Cost
Operating costs are undoubtedly one of the largest costs in the manufacturing process, in terms of running equipment, hiring employees, maintenance, and countless other factors within the factory. By utilising manufacturing control software, you are reducing costs by eliminating reasons for error, maximising materials, and operating in a smart way.

7. Advanced Planning & Scheduling
You can efficiently optimise production within your factory through the use of the technology available in. Take it a step further by integrating your software with your ERP systems and solve bottlenecks in the process, improve your delivery performance, reduce inventory, and more.

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How Opie Group Transformed Processes with Manufacturing Control Software

“Previously, we had no data available to determine where our inefficiencies were throughout the production process and where we needed to focus to improve. Now we can pinpoint exactly where we need to focus, what needs to be done and how we can fix it” – Tristan Opie, CEO Opie Group

Making the Smart Factory Leap
Established in 1962, the Opie Manufacturing Group – an Australian fabricated metal manufacturer – has been part of the smart factory transformation, and is fully embracing the benefits of manufacturing control software.

The Problem
Prior to November 2018, Opie Group’s machines were operating independently not only of each other, necessitating manual intervention in the production process, but of the customer care process – leading to a lack of visibility when it came to understanding what stage of the production process a project was at.

The Solution
Opie Group sought to remedy the piecemeal nature of their production processes with automated, round-the-clock service, delivering efficiencies across the production process while transforming the customer experience. Since November 2018 Opie Group has invested in connected machinery to automate their manufacturing processes and customer communications system, which means less idle machine time, ease of production planning, and swift customer care. No more blind spots!

The Technology
Opie Group integrated four essential pieces of system technology that allowed their machines to talk to each other as well as to the production and customer care team. The first was TruTops Fab, which allows the user to instantly convert jobs into works orders and to start production. Second was TruTops Boost for 2D / 3D design and programming of laser, punching and bending machines. Third was TruTops Calculate, and the fourth was the NetSuite CRM / ERP system for customer date management and finance administration.

The Results
By connecting their NetSuite CRM system to TruTops Fab and TruTops Boost, Opie Group has control over the entire production process, managing customer orders right through to shipping, with constant visibility of the status of production.

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