Using the new system, Customer Orders are processed immediately by the Harmony system with Works Orders being produced in small batches as required throughout the day. With real-time communications down to the factory floor, finished goods can now be produced within the hour and delivered promptly to the company's demanding customers. Alan Waterworth, YKK's Project Leader is enthusiastic about the improvements. "Before the Shop-floor System was introduced, the best we could achieve was a one to two day turnaround on our Customer Orders. Now, we can respond to important Orders within the hour if necessary. Needless to say, our customers are delighted"
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Bar-code Scanning is the key |
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The new system links bar-code printers and scanners located in each manufacturing cell with the AS/400 based Harmony system. This enables bar-coded Works Order to be printed directly within the selected cell on demand, eliminating unnecessary administration and paperwork. Production feedback from the factory shop floor is immediate so the company's sales administration staff are completely up-to-date with the progress of all Works Orders through the manufacturing process.
Following a pilot implementation in a first shop-floor cell, the system was soon rolled out to the Nylon Zipper production lines. Work is now in hand to extend the rollout to the Metal Zipper lines. Alan Waterworth concluded, "The shop-floor system has really made an enormous difference. It's completely streamlined the administrative side of our Order management process and has improved customer service significantly"
