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Applied IE

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Real-time Performance Scoreboards
Applied IE developed a simple and cost-effective method to display real-time performance scoreboards using SAP Crystal Reports and SaberLogic Logicity.
Scoreboards are large display boards containing company or production metrics.  The display board progressed  from using simple alphanumeric LED boards to large-0screen monitors displaying metrics in pragical format.
Developing scoreboards using Crystal Reports is arobust platform that use current company client-server infrastructure to directly acccess system data.  Unlike most scoreboarding solutions, this approach doesn't require the installation of an addictional proprietary server to compile and display metrics.
The SaberLogic crystal viewer Logicity Professional prepares the scoreboard design for viewing on a full-screen and a timed interval to refresh the metrics.  Logicity Professsional provides functional features that are absent in SAP Crystal Reports.
We have solutions to make your company Faster, Better, Easier. 
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Applied IE

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Language Translation of Training Documents

Like most countries around the world, we find ourselves in a place with a multitude of beautiful languages and dialects. A more complex situation for organizations striving for process compliance and looking for tools to improve training effectiveness.

Microsoft© Translate is one of many language translators available. It is a free, real-time, in-place language translator that preserves the document format. Designed for translating web pages, it can be used for internal documents residing within an organization server network.

The Microsoft© Translate widget is embedded in the training document and requires internet access for the translation engine. Users select the language preference from a drop-down menu of 32 languages. We recommend masking the bottom section of the widget to disable the utility to email documents.

Using a language translator enables an organization to provide training documents for employees to independently reference and use as an aide to improve training effectiveness. Organizations will continue to conduct a formal training process which includes a trainer-trainee session and training effectiveness assessment.

Contact us on how to deploy an effective system to improve process compliance.
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Frustrated at Extracting Data?

Get the Data You Need: There is no reason why you can't access data from an Enterprise Resource Planning system, accounting software or any information system. To freely retrieve and analyze data you will need to (1) set up a Data Source Connection, (2) study the database structure, and (3) select the software application to extract and analyze the data.

1 Data Source Connection: Use the OBDC Data Source Administrator utility that comes standard with your Windows 7 computer to access data sources located in a server. A one-time setup is required and IT support may be needed.

2 Study the Database Structure: Get a copy of the "Data Table Structure" from the software developer or ask the IT department to print it using the SQL Server Management Studio software. Study the database structure before accessing the data. It is a listing of all files (tables) in the database and the data elements (fields) in each table. Being familiar with the data table structure makes it faster and easier to access and analyze data.

3 Select the Software: Microsoft Excel may be used for infrequent data downloading for analysis. Use SAP Crystal Reports for frequent-use and multi-user reports. Crystal Reports is the gold-standard for extracting data and creating reports for majority of the information systems in the market. There are a lot of learning resources available that makes it easy to learn Crystal Reports.

Go ahead, demand access to the data you need.
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Applied IE

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High Compliance with Practical Procedures

A procedure that doesn’t make sense to end-users is naturally ignored.  No amount of training and enforcement will ever make people follow impractical procedures.  Follow the 3 Reals for no nonsense procedures:

Real Scene Go to the work area where the procedure will be performed.  Make sure you simulate the process at the work center surrounded by the people, machine, materials, methods and data.

Real Thing Simulate the process by using the work center resources.  For a production work center, build a sub-assembly or product.

Real Plan Develop a procedure based on the available resources as long as it doesn’t compromise safety, quality, delivery and cost.     
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Electronic Production Records

Manufacturers with electronic records report productivity gains of 30% to 40%. Electronic records enable production operators to autonomously complete work orders. It provides manufacturing specifications, data entry forms and performance feedback at each work station.

A successful implementation of electronic records is best done in phases starting with the (1) Part Master, (2) Quality Inspection Records and (3) Batch Records. Starting the implementation with protected read-only Part Master Specifications eliminates the document control issues of paper-based specifications. It is also a good introduction for production operators at using thin-client network terminals without the fear of messing up the computer system.
The database includes a Part Master and a Production Batch Record. The Part Master contains production specifications and standards such as drawings, procedures, quality control plan. The Batch Record documents production activities, quality inspections and resources used.
Operator data entry starts with the Quality Records phase, enabling the Quality staff to monitor Control Plan compliance and conduct statistical analysis for process capability or Gage R&R. We recommend starting the Quality Records phase no sooner than a month after implementing the Part Master phase.
The Batch Record database contains key fields that link it to the Part Master database, ERP system or Accounting system. The Batch Record contains product traceability data such as raw material lot numbers, identification of operators, production time and quality inspection records. Electronic records provide a good platform for controlling the release of updates specifications and conducting production data analysis for Operational Intelligence.

Using SQL for the back-end database enables an organization to easily integrate data reporting with ERP and accounting systems. Intuitively, the implementation of electronic production records includes the use of barcoding for speed and accuracy of data capture. Explore the use of electronic production records; it is a utility that greatly impact quality and productivity.
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How can a Supervsior Manage 72 People?

Performance-based Work Teams
A company can leverage a supervisor to manage up to 72 people by creating performance-based work groups. A supervisor can manage up to 8 work teams with 9 employees per team led a by working team leader. We recommend rotating the team leader role every 3 months making it a standard function of every employee. Key performance measures and standards of performance provide guidance to the team and enable them to identify systemic issues.

Support Staff Structure
The supervisor routinely meets with the Team Leaders 2-hours after the start of each shift to review performance metrics and review escalated issues that require corrective action. Members of functional departments such as Quality, Engineering, and Maintenance may attend the routine "Support Staff" meeting.

Training and Visual Scoreboards
The most critical training component is for supervisors to learn how to manage teams through performance measures and using Team Leaders as the main resource to direct day-to-day work team activities. For Team Leaders, a structured reporting process must be in place to collect performance data, post a visual scoreboard, and gather performance feedback from the team.

Leadership Role
Use this approach to leverage the professional skills of supervisors and managers and delegate day-to-day activities to working Team Leaders. This approach provides a structured process for all employees to step up into a leadership position during and after the Team Leader rotation.

Numerous companies in various industries adopted this approach to streamline the management structure, create a cascade of performance metrics and implement a disciplined work force with high process compliance.
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Introduction

Applied IE is a management consulting firm with extensive knowledge and experience is business management, manufacturing operations, Quality Systems, Industrial Engineering and information technology application.  Broad experience in industries such as anodizing, automotive, computer technology, consumer products, electronics, extrusion, insurance, fabrication, machining, medical-device, pharmaceutical, plastics, printing and steel.

Experienced Project Managers.  Successfully managed project such as the launch of a global accounting system for a pharmaceutical company, the design-construction of a manufacturing facility, and deployment of leading-edge digital print technology with six-sigma quality level for a surgical-device manufacturer.

Knowledgeable Information Technology Professionals with expertise in Decision Support Systems and experience in developing manufacturing electronic records.  Expert-level skills in Operational Intelligence and Business Intelligence data mining, statistical analysis and reporting.

Multi-faceted Process Engineers with an extensive array of methods, techniques and tools to successfully implement project initiatives.  Optimized month-end financial consolidation cycle time of 220 global entities by 54%.  Reconfigured packaging line resulting in a headcount reduction of 45% and improved changeover time by 83%.  Improved custom steel casting order cycle time by 62%.  Designed mixing vessels with 50% less blending time.

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