With so many manufacturing productivity tools available, why is Versacall an attractive solution?
The short answer is: Results!
The slightly longer answer is: Our simple solutions are amazingly effective because they work with human nature and address common production downtime issues. Since all companies have different needs and goals, we tend to customize our products for optimal performance in each unique factory environment, and hence our solutions are quick to implement.
Let’s face it, change is hard and human nature tends to resist it. Yet manufacturers need to change if they want improvements. Otherwise it is similar to the definition of insanity: “To do the same thing over and over and expecting a different result”.
So knowing that change may be difficult, the first decisions to make are why and where to change.
Why change? To reduce cost of production.
Where to change? Consider the cost of downtime.
When analyzing contributing factors to unnecessary production costs, downtime is usually the biggest factor. Virtually all the factory costs continue during production stoppage, while no value-added manufacturing occurs. More importantly, however, is the opportunity costs resulting from not manufacturing products that otherwise would have been shipped to customers and sold at a profit. Each unnecessary minute of production stoppage costs a fortune. Click here for a convenient downtime cost calculator for your factory.
Another perhaps just as significant factor of downtime is the cost of not being able to deliver products to customers at the timeline agreed upon.
What tend to be the largest culprits of production downtime?
- Machines or workstations waiting for parts to process
- Equipment breakdown
- Response and resolve times
Versacall drives downtime improvements utilizing three approaches:
Fix issues quickly. A simple call system where the operator pushes a button (or mouse click) for support, for example from Maintenance, Parts Dept., Supervisor or other. The call (or text, or pager etc.) starts a timer which incentivizes quick response. When the relevant personnel is on-site to help with the issue the clock stops. It immediately starts anew to measure resolve time. Again, this incentivizes quick action. When the clock is ticking people pay attention!
Make it visible. Real-time dashboards on TV monitors in the factory and on authorized PCs & mobile devices provide instant status and insight. Each factory may choose what data they want to see on their visual management tools, but production status, response/resolve times, cycle time, and production progress status versus target, are common data. Again, when people can see what’s going on they will act to improve!
Fix the issues before they happen. The calls for support in the factory can include basic data such as reason code, missing part numbers, cycle time etc. Compiled reports provide insight and reveal trouble areas and trends. This information allows engineers to proactively improve specific processes with the goal to avoid issues that lead to downtime in the first place. In other words, fix the problems before they lead to downtime!
At Versacall we do not look upon customization as cost of doing business, rather we embrace it as value generating. We have an entire department working with customers to mold the technology into a complete system that works well in their factory. And when needs and conditions change over time, they are again working with customers to make the Versacall system accommodate those needs. We can also share the data and reports we generate with our software systems in the factory.
- Average response time reduced from 30 minutes to 5 minutes.
- $590,000 annual reduction in production cost
- 5%- 12% increase in production output
- 10%-12% reduction in downtime
- Average response time dropped from 25 minutes to 5 minutes
Alerting and visualizing status enable factory personnel to make better decisions and to act faster. Implementation of such simple improvements are quick, easy, inexpensive, and embraced by factory personnel. Improved communication, production visibility, and actionable data improve productivity. It’s that simple!