## What is 5S?

5S, often referred to as Lean 5S, is a philosophy that focuses on identifying key items in your process, getting rid of unnecessary items, and optimizing the operation’s workflow with standardized and sustainable methods. 

The 5S methodology is centered around 5 Japanese S words which are conveniently translated into 5 words beginning with S in English. 

<img src="https://strapi.vksapp.com/uploads/5_S_e29e4b6ca0.jpg" alt="5S" className="center">

By focusing on the key methodologies attached to these 5 points, companies are able to organize and optimize their efficiency and productivity.  


## What are the 5 S’s

Let's take a look at each of the 5 S's and highlight some key measures for each S.  When beginning your 5S journey, each step should be done sequentially. However, after the process has been completed, each S should be an ongoing venture for all departments. The idea is to never stop cleaning, never stop organizing, and never stop optimizing. 

### 1. Seiri - Sort 

The first S is Seiri, which, when translated into English, means “sort”. In this step, you’ll want to take a good hard look at your production items. This includes:

- Parts
- Materials
- Tools
- Procedures

Once you’ve identified your production items, you’ll need to sort everything out into two categories, **needed and unneeded**. This can also be categorized as **necessary and wasteful**. 


A good way to determine if something is necessary or wasteful is to look at it from the perspective of the customer. Ask yourself: Does this directly or indirectly add value to the customer? If yes, keep it and enhance it. If not, throw it out. 

Now, when considering parts and materials, sorting means removing them from the production space. This way, users and machine layout are not encumbered with unnecessary materials. But, we surely don’t want to throw out everything that is not in use. If money has been spent, then it’s best to use these materials to their fullest and slowly progress to <a href="https://vksapp.com/blog/push-vs-pull-manufacturing">smarter inventory measures</a>. 

However, if there are no plans to use these materials and a lack of space is affecting production efficiency, then perhaps the items should be sold or removed entirely. 

Intelligently sorting through your production items in this manner helps to clean up the production line of unnecessary items so that the operation is less distracted, less complex, more spacious, and more open to an enhanced and streamlined setup.

### 2. Seiton - Set in Order

In this next step, take all the items left from “sorting” and “set them in order” for ease of use. This means placing these necessary items in the optimal place so that the operation can be streamlined. 

The goal of this step is to make everything flow in an optimal order so that physical elements, as well as employee workflow, are simple and effective. Here are some key methods that help companies increase flow and order. 

- Place tools and equipment close together in a specific order of operation to limit travel time between workstations.
- When short on space, arrange machines, parts, and tools with the highest frequency closest to the workplace.
- Introduce consistency by setting up fixed locations for production items so that production resources are easily found and accessible. 

### 3. Seiso - Shine

They say *cleanliness is next to godliness*, and there may be a bit of truth to that. A <a href="https://vksapp.com/blog/konmari-5s">clean and organized working environment</a> can often protect manufacturers from workplace accidents, product defects, and low employee morale. 

To implement Seiso, perform the 2 following actions and make your operation shine!

1. Clean the workplace at regular intervals: 
2. While cleaning, use the time to inspect equipment and the workplace. 

Cleaning can be done daily or at another predetermined frequency but it should be done often. This also gives your operators the chance to inspect the workplace, the equipment, and their tools for any issues that would normally go unnoticed. 


Create specific cleaning and inspection guidebooks within VKS to ensure that everything meets the exact standards of your company and 5S methodologies. 

### 4. Seiketsu - Standardize

Now, you’ll need to standardize the above processes. Sorting, arranging, and cleaning need to be established as the <a href="https://vksapp.com/dictionary/standard-operating-procedure">standard operating procedure</a>. And these standards need to be easily repeatable. 

To accomplish this, you can do the following. 

- Establish a comprehensive structure that enables the best practices to be accessed and followed.
- Provide process documentation to ensure that everyone knows their tasks and responsibilities.
- Use photos and other visual control methods to verify compliance.
- Create checklists to review standardization methods regularly. 


Use <a href="https://vksapp.com/work-instruction-software">work instruction software</a> to accomplish all of the above methods. Create standardized digital work instructions that guide workers through every step of their tasks and responsibilities. This ensures that the best practices are followed every time.

### 5. Shitsuke - Sustain

The last step in Lean 5S is to make these processes sustainable. You can do this by performing the following.

- Schedule regular training sessions so that all employees stay on track with the 5S philosophy and methodology.
- Ensure that all practices and methods can be carried out over the long run.
- Perform 5S audits regularly to ensure measures are being followed.
- Discover and implement improvements over time. 

The last point is crucial for modern businesses. We may get the idea that sustainability is about keeping things the way they are or maintaining the status quo. But for every operation, Sustainability should mean a whole lot more than that. 

Sustainability is about keeping an eye on the future and creating new practices that keep your company alive and thriving. As technology, workforces, and methods change over time, companies will have to find new ways to maintain growth and sustainability. 

### Bonus S: Safety

Through the popularity and improvement initiatives brought on by 5S methodologies, some have seen fit to add a 6th S to the philosophy: *Safety*. 

In this step, you’ll need to identify hazards, perform risk assessments, and establish preventative measures. In many ways, the 6th S is a review of the 5S methodology with a keen focus on preventing hazards and sustaining safe practices. 

Preventative measures can be any of the following actions:

- Removal of unnecessary risks
- Establishing PPE requirements
- Distribution of safe standardized practices
- Institute administrative controls such as safety policies
- Create better <a href="https://vksapp.com/blog/real-time-learning-vs-training">training modules</a>
- Change company culture to think about safety


Each one of these safety measures can be accomplished with <a href="https://vksapp.com/dictionary/standard-operating-procedure">https://vksapp.com/products/lite</a>. Establish best practices, ensure safety compliance, create effective training programs, and improve employee safety engagement with one purpose-built software.

5S, often referred to as Lean 5S, is a philosophy that focuses on identifying key items in your process, getting rid of unnecessary items, and optimizing the operation’s workflow with standardized and sustainable methods. 

Initially developed for use in the 1970s, additive manufacturing has evolved much since its inception to allow for personal and industrial precision use in nearly every field imaginable. Examples vary in complexity from a hot glue gun to a precision-cutting electron beam.

Key Takeaways

## What is Additive Manufacturing?

Additive manufacturing is best understood as the opposite of **subtractive manufacturing**. Subtractive manufacturing is something like whittling or stonemasonry, where the worker skillfully takes mass away from the material with a sharp tool, eventually shaping a usable item.

So, to further the analogy, additive manufacturing is adding more mass onto another material in order to create a usable object of greater dimension. 

Additive manufacturing works by laying down (“printing”) a very thin layer of material one cross-section at a time, each on top of the last, to create a 3D object. Although this process gives the illusion of making something from thin air, the high-precision printing machinery is impeccably fine-tuned to heat and cool different parts of the structure at the molecular level so that the layers fuse and are set in place.


## The Beneficial Applications of Additive Manufacturing

Have you ever had a favorite appliance or piece of equipment or furniture suddenly break? To buy a substitute just won’t do – the entire product is either too expensive, or too precious to the user to be replaced; the favorite item also may be discontinued, and replaceable parts are no longer available!

*This is where 3D printing comes to save the day.*

With additive manufacturing, almost any replaceable part that wears down or fails can be custom-made for a reasonable price. This has ushered in a new love for recycling, replacing, and widely supplying specific mechanical needs in both personal and industrial settings.

Here are a few highlights of the infinite possibilities for additive manufacturing applications:

- Customized pieces for specific projects that otherwise would not provide a high-enough ROI for a company to undertake
- Up to 90% less material waste compared to subtractive manufacturing
- Uses environmentally friendly, biodegradable plastic materials
- Precise geometric design and physics
- Encourages visual design in problem-solving for engineers
- Increased accessibility for individuals to create and repair items
- Allows for creative learning and instruction
- Extends longevity of machinery, even machines that have been commercially discontinued
- 3D-printed meat can help solve the food industry's strained demand for animal proteins
- Lifesaving healthcare wearables are cheaper and more plentiful for the average person
- Ability to easily create highly complex, perfectly measured geometric shapes
- Rapid prototyping allows for more effective and cost-efficient R&D

The benefits and applications are almost too many to count. One of the more pressing solutions provided by additive manufacturing of late was a response to the PPE shortage at the beginning of the COVID pandemic. When supply chains failed to deliver PPE on short notice, <a href="https://www.nihlibrary.nih.gov/services/3d-printing-service/3d-printing-medical-equipment-response-covid-19-pandemic">individuals began 3D printing parts and new wearable solutions</a> for those at the medical front lines, which helped mitigate the international shortage.



## The Hazards of Additive Manufacturing

As with any new technology, innovative futures are tempered by the inherent risks. With additive manufacturing, the risks of increased use of this technology are somewhat unique:

First, there is a danger of eroding intellectual property standards. If a person has the same 3D printer as another, they can duplicate their products fairly easily. However, this has the opposite effect when it comes to price gouging of patented parts; knowledge and ease of product replication can help drive down excessive costs imposed by bureaucratic or corporate authorities.

Second, there is the risk of quality control when it comes to safety. Because of the increased accessibility of additive manufacturing along with decreased costs up front, some individuals flaunt personal responsibility and federal laws. 

For example, there is a growing concern that as 3D printing technology improves, so will the ability for individuals to supersede registration laws and <a href="https://slate.com/technology/2021/02/3d-printed-semi-automatic-rifle-fgc-9.html">print their own firearms and gun parts</a>. 

Not only is this dangerous in the obvious sense, but the lack of quality testing in this scenario would also mean a higher probability of product failure, which would lead to even more risks to health and safety. This same problem exists in the health industries: if certain medical device parts are 3D printed en masse to be more accessible and affordable, they also must have the utmost assurance of durability and high performance. 


## The 7 Types of Additive Manufacturing

There are seven types of additive manufacturing, even though as technology improves, the categorization and naming also shifts alongside innovation.

### 1. Binder Jetting

This type of 3D printing involves applying an adhesive binding solution to layers of powdered ceramic or metal in the cross-section using an inkjet-like process.



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### 2. Directed Energy Deposition (DED)

This type of additive manufacturing uses a laser beam to melt bits of metal (or metal powder) into a layer of material. This category also includes gas metal arc welding and freeform fabrication using an electron beam.

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### 3. Material Extrusion

The most commonly known form of accessible additive manufacturing is material extrusion, which applies plastic filament in thin layers to create a final product. It is done using a fused filament fabrication (FFF) machine. This type of AM machine has a low cost (around a few hundred dollars) and can be used for home applications, but it has major limitations as to the size, orientation, and lasting functionality of the objects it can create.



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### 4. Powder Bed Fusion

This technique uses laser sintering, laser melting, and electron beam melting to fuse metals and polymers together. This fusing is done within a granular bed for greater temporary support.


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### 5. Sheet Lamination

In this field of additive manufacturing, cheaper materials like paper, plastic, and metals are bonded together with adhesive in thin layers and pressed tightly until bonded. A tungsten blade can perform final detailed cuts to the final product.


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### 6. Stereolithography

Also known as “vat polymerization”, stereolithography is the process of curing liquid material – such as resins – into solid using ultraviolet (UV) light. The controlled light exposure causes polymerization; covalent bonds form between the layers of added material and strengthen the product.



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### 7. Material Jetting

This technique of additive manufacturing is very similar to binder jetting, but in this version, added material is added droplet by droplet in a wax-like layer directly on top of the object in production, without a granular bed of powder for support. This method is fairly inexpensive compared to others, but produces a weaker final object.

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## How to Choose the Right Additive Manufacturing Method

By nature, additive manufacturing is a wild card that can fill almost any role required of it. Because of this, it’s best to *work backwards logically*.

In other words, don’t ask yourself what you can do to promote more additive manufacturing, ask yourself what additive manufacturing can do for *you*.

Sure, you can upgrade all your industrial machinery with the latest versions of 3D printers, but the best perspective on additive manufacturing is to consider it like a swiss army knife, applicable in almost any scenario that needs a custom, individual solution.

Also, remember to think out of the box – er, 3D printing bed – when considering solutions, because you never know when a new 3D application will catalyze a new method of additive manufacturing completely, so experiment away!


Additive manufacturing is the application of 3D printing and rapid prototyping technologies in an industrial setting. From hot glue guns to electron beams, these AM tools add mass to materials to produce final objects.

## What is Agile Manufacturing?

Agile Manufacturing is a production methodology that enables companies to be agile in the face of change. As customer expectations shift and opportunities for innovations arise, Agile manufacturers are able to shift their strategies quickly and responsively. 

The consumer and industrial markets change quickly and very often. Regardless of the product or the operation, manufacturers that do not meet market demand will be left behind by competitors that can give consumers what they want, when they want it. 

Let’s explore Agile Manufacturing, what it does, how it accomplishes certain goals, and if it is the right practice for you.


## 4 Key Elements of Agile Manufacturing

Agile Manufacturing is all about turning speed and agility into a key competitive advantage.

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### 1. Customer Focus

The customer is paramount within Agile Manufacturing. While pursuing market flexibility and optimizing operational efficiency is good, if the customer is unwilling to pay for the product, then your agile methods have failed.

### 2. Modular Product Design

Instead of looking at one product as a whole, agile manufacturers will produce their products with a modular design. Each product is made up of various parts and processes which can be quickly changed or varied based on the needs of the market.

### 3. Information Technology

Knowledge is power. And the more your employees and systems have access to this knowledge, the faster and more agile your company will be to sudden shifts in the market. With greater transparency and visibility, companies are pursuing greater responsiveness to their customers. 

### 4. Inter & Intra-Company Involvement 

Within Agile Manufacturing, every department and every partner needs to be connected. From marketing, design, production, and distribution, the whole company needs to be tapped into a database that gives them access to information on materials, production capacity, delivery times, and potential issues. 

## Why Use Agile Manufacturing?

With the growth of e-commerce year over year, consumers are more demanding than ever. And their tastes and preferences are constantly evolving from month to month and even day to day. With all that Agile Methodology has to offer the industry, it is especially useful for companies with the 2 following characteristics.

1. Companies within countries where labor costs are above the global average.

For these types of companies, competing with offshore prices is not a viable option. But what they do have is greater control over their workforce, providing them with flexibility and resiliency to market shifts. 

2. Companies that are geographically close to their indented market.

If close to the intended market, companies have greater control over their production and distribution. This leads to a more agile operation that also experiences shorter lead times.

## Customer Benefits of Agile Manufacturing

Agile companies leverage their operation and methodology to provide a more responsive relationship with their customers and their needs. Progressively, consumers are getting used to 3 major factors while purchasing. 

- **Fast and Responsive Delivery**: Consumers love getting their packages as soon as possible. As we have seen with Amazon Prime, users are willing to pay monthly fees just to get their products quicker. If manufacturers are geographically close to their customers, then the business can deliver their product that much sooner, leading to greater customer satisfaction.
- **Product Personalization**: 100 years ago, when buying a blender, it came in only one size, one speed, and one color. Now, no matter what kitchen appliance, most major brands will have a variety of options to choose from. This enables customers to have a greater degree of personalization from their purchases. Agile practices enable companies to provide a varied line of products that customers can choose from without wasting time, money, or materials. 
- **Product Innovation**: Agile practices enable companies to be responsive to consumer demand and get innovations out on the market sooner. As soon as needs arise within the market, an agile company will be able to augment their product and their operation to meet those new needs. 

If a company is not sufficiently agile, they will struggle to keep up with the ever-changing demands and growing expectations of the market. 

## Agile Manufacturing vs. Lean Manufacturing

Lean and Agile can be understood as a person being lean and/or athletic. Often, companies will become Lean before they become athletic or Agile. They will first focus on cutting out waste and this enables them, in part, to pursue a more Agile methodology. Though, it should be stated that companies can be Agile and responsive to market demands while still producing a lot of waste. 

The main difference between the two is that Lean production methods focus on optimizing production whereas Agile Manufacturing focuses on optimizing customization, variety, and product evolution. This is an incredible methodology for mixed-model, <a href="https://vksapp.com/blog/mts-mto-ato-how-you-can-use-these-strategies">MTO, MTS, or ATO</a> operations. As customers want newer and better products more quickly, an Agile company can fulfill these demands sooner. 

## What’s Your COC Time?

When looking at whether your company should adopt lean practices, agile practices, or both, companies need to take a look at their COC (customer order cycle). If your COC is fairly short and products are completed soon after the order has been made, then you have a lot of opportunities to change production based on the changing market.

Conversely, if your business is characterized by longer COC times, like aircraft manufacturers that gain specific contracts that last years, you may not be able to reap all the benefits that Agile Manufacturing has to offer. 

At the end of the day, within Lean and Agile methodologies, one is not greater than the other. It all depends on your production. 

## Is Agile Manufacturing Right for You?

As consumers’ expectations progressively move towards more choice, faster delivery, and frequent innovation, Agile Manufacturing is the right solution for companies looking to gain a competitive edge, especially over offshore companies. If your company is close to the intended market and has short COC times, then you will be able to optimally reap the benefits of Agile methodologies. 

But within any manufacturing style, every company can benefit from better communication and responsive actions to the market. Tools like our <a href="https://vksapp.com/work-instruction-software">work instruction software</a> help companies supercharge their capabilities and pursue both Agile and Lean success. 



Agile Manufacturing is a production methodology that enables companies to be agile in the face of change. As customer expectations shift and opportunities for innovations arise, Agile manufacturers are able to shift their strategies quickly and responsively. 

## What is Andon? 

In manufacturing, Andon is a system that enables workers to quickly notify team members and managerial staff of quality or process problems. Typically, Andon is performed by activating a light on a signboard that specifies which workstation has either noticed the quality issue or is experiencing problems.

Andon is a Japanese term roughly translated as “lantern”. And it's not hard to see why the process was given its name. Andon serves to illuminate problems on the production line as soon as workers see an issue. This enables companies to enact quick responses to problems and pursue continuous improvement frequently. 

## Brief History of Andon 

Like many Lean Manufacturing tools and practices, the Toyota Production System (TPS) is responsible for this innovation shortly after WWII. 

In early renditions of this practice, when operators noticed an error or had concerns about quality, they would pull the Andon cord. This would stop production and light up a signal board, indicating where the problem was and which workstation pulled the cord. Managers and supervisors would immediately go to the workstation and work to resolve the issue or improve the process. 

What’s interesting is that the whole production stopped every time the cord was pulled. It could be pulled by anyone on the line and it was pulled often. For Toyota, this was a key tool to enacting continuous improvement and changing the manufacturing culture to pursue quality and value at every turn. It didn’t matter that production was slowed down, it was worth it to make the product and the process better and better.

## Andon & Modern Lean Manufacturing

Though the days of the physical cord may be over, Andon has grown to take many forms and methods around the world. Now, operators can push a button, activate it through their <a href="https://vksapp.com/work-instruction-software">work instruction software</a>, or it can be autonomously activated by equipment and software when problems are perceived. 



This practice makes Andon a key Lean Manufacturing tool as it also changes a company’s perspective and culture on problem-solving. Lean is first and foremost a culture within a company. 

**The Andon light shouldn’t spark fear because of an identified problem, it sparks progress because it identifies areas for growth.**

Workers need to feel free to speak up when they see issues or mistakes. The company in turn needs to see every failure as an opportunity to increase value, reduce waste, and pursue improvement.

### Andon: 2 Ways

Andon is typically used to make 2 types of advancements.

1. Fix quality issues
2. Improve processes

For example, imagine a company fabricates and builds <a href="https://vksapp.com/industries/rail">locomotive engines</a>. These engines require several processes and people before the final product can be sent out. This includes welding, assembly, electrical wiring, and more. 

One of your assembly employees notices that a weld looks abnormal on one of the pipe fittings. Upon further inspection, she sees that the weld may not supply the adequate strength needed. She goes to VKS and activates Andon. The work instructions are paused and the supervisors are on their way. 

This quick response allows workers and managerial staff to quickly resolve the issue. They take a look at the weld in question and concur that the weld is defective. Now they have the opportunity to perform a root cause analysis and inquire with the welding department to resolve the quality issue. 

Because the error was caught early and the employee felt free and obligated to notice problems, the quality issue was fixed early in the process. 


Use <a href="https://vksapp.com/dictionary/smart-forms">VKS Smart Forms</a> to quickly inform the right people of quality issues or process improvements. 

## Benefits of Andon 

As we have seen, Andon supplies companies with a unique operations culture. By simply switching their perspective and illuminating errors, companies experience the following benefits: 

- **Operational transparency**: With Andon, nothing is hidden. Companies gain a live view of their operational defects and inefficiencies. 
- **Removal of bias**: When Andon is activated, leaders need to “go see” the issue for themselves. This removes pre-conceived notions and potential biases that anyone may have. 
- **Failure leading to success**: Workers are encouraged to share problems, failures, and possible improvements as they are noticed. This leads to greater opportunities for improvement. 
- **Decreased waste**: As a Lean Manufacturing Tool, Andon works to eliminate waste as soon as it occurs. 
- **Increased value**: If the product and process are actively improving according to the needs of the customer and the company, then the value is also always improving. 
- **Responsible and empowered operators**: Employees under the Andon and Lean Manufacturing culture take responsibility for the work they perform. They are empowered to be active instead of passively waiting for managers to enact improvements. 

Discover how Andon enables workers to quickly notify team members and managerial staff of quality or process problems. Typically, Andon is performed by activating a light on a signboard that specifies which workstation has either noticed the quality issue or is experiencing problems.

## What Is an API?

An API (Application Programming Interface) is a set of code that enable two or more systems to connect and share data. As opposed to a user interface that serves to connect programs with people, APIs are used to connect programs with other programs. 

Why have APIs become such a large topic over the past few years and what can they do? 

APIs are extensively used all over the world to connect businesses, exchange data, and enhance programming capabilities. Companies like Facebook, Amazon, and Google all develop their own APIs to give other programs tailored data without handing over complete access to their ecosystem.


## The Restaurant Example

To get a firm grasp on what an API is, imagine you are hungry for some gourmet burgers, but you don’t have the capability to make them yourself. So you go to the new gourmet burger restaurant in town. You want to order some food and the kitchen is ready to make it for you. But how do you relay your order to the kitchen staff? 

This is of course done through the waiter. He is the critical link between you and the kitchen.
Without the waiter, you would not be able to interact with the kitchen and they would be unable to serve you the burger. But the waiter allows you to enhance your dining capabilities through a connection with the kitchen. 

In this example, the waiter is the API of the restaurant while you and the kitchen are two separate systems. With the API connecting these two systems, complex procedures can be performed by simply asking for them. In this way, an API serves to optimize and extend the functionality of the two systems by connecting them. 

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## Where are APIs Used?

APIs are used all over the world. They are the engine under the hood of global connectivity. Online recipes, music, maps, parking space availabilities, and more are all made possible and enhanced daily by APIs. In reality, it is very hard to find an internet application that does not use an API to some degree. 

### API Example 1

Take, for instance, buying ballet tickets online through a third-party ticket service. The service does not own the seats at the theater but simply has access to a database through the theater’s API. This capability enables them to sell tickets and automatically update the event’s database.

### API Example 2

The maker of your smartphone is not a weather company, yet it has up to the minute data on the weather all over the globe. This data is provided by companies like The Weather Channel. They have sensors around the globe and their API enables your phone to have access to their database in order to receive weather updates. 


Whether you are looking to connect VKS with your ERP,  MES, or any Business Intelligence Platform, we provide turnkey services to build the necessary connections and integrations between your various software suites.

## API Power: 4 Key Attributes

### 1. Critical Exchange of Data 

APIs open up the doorway to an enhanced data exchange between systems, giving you the best and most current data when you need it. 

Let’s continue the restaurant example. When you want to know more about your order, you simply need to ask your waiter. He can then provide you with needed information about the food, regular updates on how long you’ll be waiting, and much more. 

We can see this in a real-life example with the weather app built into any iPhone. Apple is not a weather company. They do not have weather sensors all around the globe. Rather they are pulling data from the API of forecasters like The Weather Channel. 

In the same way, APIs enable systems like <a href="https://vksapp.com/work-instruction-software">VKS work instruction software</a> to exchange information with other systems like ERPs (Enterprise Resource Planning) and MES (Manufacturing Execution System). 

### 2. Simplify Program Complexity

APIs also serve to simplify functions that would otherwise be complex. As data is exchanged, the programs can facilitate each other by efficiently automating critical tasks.

Imagine you’re back at the restaurant and they are serving a lovely chocolate lava cake that sings to you while the molten ganache is flowing out. You don’t need to know how to make this fantastical dessert. Since you are with the waiter, you only need to order it. The kitchen will take care of the rest. 

Similarly, API-enabled programs don’t need to know how to connect to the internet or take a picture using the device camera. They simply need to ask the operating system to do it for them. It doesn’t matter what device or operating system the program is using, it only matters that there is a connector exchanging information between the two or more programs.

APIs enable programs to achieve new levels of integration and teamwork with other systems.

### 3. Extended Functionality

APIs enable systems to extend their functionality based on the programs they are connected to. We’ve all seen this happen on our phones. One program is asking for permission to access our camera or use our current location. This is the program using its API to connect with data sources and devices within our phone. 



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What’s incredible is that the possibilities are seemingly endless. Imagine the potential of integrating every system within your operation and supply chain. Now each program feeds off of the information and capabilities of other systems. 

Think of it as adding a new member to your team. As you add more people and expertise, the capabilities of your business grow. Likewise, programs interact with other systems and extend their functionality through powerful API technology. 

### 4. Layers of Security

APIs also serve to provide layers of security the same way a passport office does. 
Think of the process of applying for a passport. Normally, the process is controlled by the passport office and shielded from the general public. Much like our waiter example, the passport clerk is the intermediary between you and the process that happens behind the counter.

As we’ve discussed, this hides a certain level of complexity where you don’t have to do anything except applying. But just as importantly, it protects the internals of the system from unwanted tampering. Since users can only interact with the teller at the passport office (API), the process is protected. 

Similarly, APIs provide systems with a level of control over how others interact with their system. APIs give users safe and strong connections that protect valuable data and processes.


An API (Application Programming Interface) is a set of code that enable two or more systems to connect and share data. As opposed to a user interface that serves to connect programs with people, APIs are used to connect programs with other programs. 

## What are Best Practices?

Best Practices are the established principle course of action within any situation. They can be used to make sure that the most efficient, cost-effective, and/or safe methods are being used. Typically, best practices are used within business applications as a way to establish the best working standards. These can come in the form of specific actions, guidelines, ethics, or ideas that enable businesses to produce optimal results. 

For best practices to work, they need to hit on two key elements:

1. They need to produce optimal results.
2. The standards need to be repeatable.

It is simple enough to say that best practices are the methods that produce the best results, but it is equally important for these practices to be easily repeatable. For example, if workers consistently lack time to do a job within the established best practice, then the practice is no longer the “best”. 

**Real best practices give companies control over their processes and the ability to produce consistent results.**

So what are best practices and how can you use big and small actions to find the best practices for your businesses?


## What Are Manufacturing Best Practices?

Within manufacturing, best practices can range from specific activities, like how to properly hold a hammer, to broad company-wide philosophies like transparency. Because of this, we can separate many manufacturing best practices into these two categories: 

- Specific Actions 
- Broad Methodologies

Specific Actions enable operators to know what action should be taken when faced with a specific task. 

Broad Methodologies help companies stay on track within more complex circumstances where an explicit best practice or action cannot be stated. 

Specific Actions Examples

- **Always lift with your legs**: When it comes to health and safety, this is probably the most frequently heard best practice. This is because it is valuable to remind employees that lifting with your legs and not your back is the required and safe methodology. 
- **Maintain the correct sequence of actions**: Imagine you run a <a href="https://vksapp.com/case-studies/smith-induspac-precision-is-key">packaging solutions company</a>: Every box and package needs to be assembled in a specific order. It may work to assemble the boxes in a different order but you and your team have determined that one specific order is the most efficient. 

Broad Methodologies Examples

- **Lean Manufacturing**: This business methodology/philosophy is essentially a set of guidelines. For example, <a href="https://vksapp.com/dictionary/lean-manufacturing">lean manufacturing</a> doesn’t tell you how to reduce waste specifically within your company, but it does help characterize opportunities for you to implement smart and efficient processes that meet the needs of your company.
- **DMAIC**: <a href="https://vksapp.com/blog/DMAIC-Approach-Intelligent-SOPs">Define, Measure, Analyse, Improve, & Control</a> is a great way to establish and improve well-performing processes. This specific data-driven sequence enables manufacturers to efficiently adapt to new technologies and methods in a well-defined and structured framework. Like lean manufacturing, this approach simply provides a framework for improvement. What methods and specific actions you use will be up to you. 

An effective way to ensure that specific actions and broad initiatives are being followed is through <a href="https://vksapp.com/work-instruction-software">work instruction software</a>. Set safety reminders and guide workers through the correct actions while opening new avenues for communication and improvement. 

## How to Establish Best Practices

When creating, developing, or improving your best practices, it is beneficial to follow a best practice. I know that may sound confusing but stick with me. To illustrate this point, let’s follow the above-mentioned DMAIC method to establish your best practices. This will enable you to find the optimal actions while setting the framework for improvement over time. 

### Define 

Here you’ll want to define the process in question. Perform a <a href="https://vksapp.com/dictionary/mes">Gemba Walk</a> to engage employees to see firsthand how the operation is done. This will give you an accurate representation of the capabilities of your workforce while including them in the decision-making process. Also, look at who is consistently producing excellent results and incorporate their actions into establishing the best practice for the procedure. 

Although going to the shop floor is a best practice in itself, having a system like an <a href="https://vksapp.com/blog/how-to-do-a-gemba-walk">MES</a> that enables you to track the productivity of your employees is a powerful and consistent tool in defining processes, complications, and achievements. It will also enable workers to communicate their ideas and funnel in more valuable knowledge.

### Measure 

Once you have defined the best practice, determine what metrics you will use to measure its effectiveness. This will enable you to accurately track progress once the best practice is integrated into the operation. 

To see this in practice, let’s use the example of **always lifting with your legs**. Determine the key metric that will accurately gauge the effectiveness of the best practice. In this case, you’ll want to measure the number of back injuries before and after the implementation of this specific best practice. 

### Analyze 

Now that you’ve determined your key metrics, you can analyze the effectiveness of the best practice. Figure out root causes and plan for greater improvement over time. When needed, modify your best practice to fit the unique needs of your operation, workforce, and goals.

This is another great opportunity to talk to workers. People are often resistant to new methods so involving them in the process will go a long way in developing a strategy that everyone is comfortable doing. 

### Improve

Here’s where you use the information you’ve gathered from analysis to improve your best practice. One specific best practice is to focus on improvements that will have the greatest impact for the better. Once these have been taken care of, you’ll have a good framework for smaller and more incremental improvements as you control the process over time. 

### Control

Everyone should be aware of the implemented best practices and have a way to review them when needed. With work instruction software that guides workers through their complex manufacturing tasks, employees gain the confidence that they are doing the right actions for every task. 

Once you’ve gone through DMAIC, you’ll want to evaluate and refine the process. As your operation changes over time, improve and refine your best practices as necessary. 

## Should Best Practices Change?

It may seem counterintuitive but best practices are indeed fluid. As businesses evolve, gain new technologies, and improve their operations, the best practices that define the company needs to grow and change with it. 

Just in terms of safety, think of all the industry standards that have changed over the past decade, let alone all the changes that occurred under the pandemic. Best practices should always follow the optimal and safest results. 

That is why it is important to use methodologies and technologies that enable your company to quickly respond to industry shifts and master change. Software like <a href="https://vksapp.com/products/lite">digital work instructions</a> helps you do this. Any improvement within a methodology or process can be updated on a company-wide scale with simply a click of a button. This allows every employee to have the most current and accurate instructions and best practices at their disposal. Remove the guesswork from your operation and firmly establish the best practices your company has to offer. 



Best Practices are the established principle course of action within any situation. They can be used to make sure that the most efficient, cost-effective, and/or safe methods are being used. 

Cloud computing is the ability to offload storage and processing power to a central physical server while allowing users to virtually access those resources anywhere at any time as long as they have an internet connection.


## What is the Cloud?

A cloud service provider hosts a remote server system available for customers to tap into and virtually access the expansive resources offered by a centralized system.

Cloud computing is what allows you to access your email on your phone, your laptop, or any device you’ve never seen before, as long as you have internet access.

Clouds are maintained through massive data centres throughout the world that host different Internet servers for the distribution of data. Like Dropbox or Google Drive, the cloud is a theoretical storage system that can house parts of the internet for future access. 

If you’ve ever switched to a newer phone and found all of your contacts, information, and emails still in the same folders, you’ve accessed your information via cloud storage!


IoT devices hooked up to the cloud as a representation of cloud computing

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## 3 Types of Cloud Computing (+1 Bonus One!)

By now you can understand why the cloud is used as a metaphor for the Internet: both concepts are amorphous, with borders or limits that are not immediately distinguishable. Just like you may not notice the morning mist that rises to become fluffy clouds, you may not notice the constant buzzing of electrical signals that build to create a global net of instant communication.

Admittedly, this is still pretty difficult to visualize at times, so it is important to at least recognize the ways in which the cloud manifests. There are three “shapes” of cloud you will encounter:


### Public Cloud

Essentially, the public cloud is the Internet. It is very similar to the private cloud in terms of architecture and infrastructure, but it is accessible to multiple users at once regardless of physical location.

An example of public cloud use would be free public wifi in city parks, where individuals can access the internet without private login credentials.

Ever heard of the phrase, *“Once it’s on the internet, it’s there forever?”* This saying highlights an important risk of the public cloud: while being an incredible source of knowledge and innovation, it spreads so massively throughout the world that you can be exponentially vulnerable to bad actors. This is why you always should be careful to protect your personal identifying information while online.


### Private Cloud

An online network specifically controlled and operated by a single user, a private cloud is especially useful for companies that have to comply with privacy laws. A private cloud keeps confidential information on a server owned and maintained by a sole operator. 

For example, a small law firm may operate on a private cloud, where all company resources are exclusively accessed from a single location with a set number of approved computers and devices for extra privacy. In this instance, workers will have to go into the office to access their work files on an approved device using approved user credentials.



### Hybrid Cloud

This is a combination of public and private clouds that allow businesses easy accessibility across the board while ensuring the privacy of certain data stores.

A company might set up cloud infrastructure in this way because they want a dual access system where executive workers with approved user credentials can access high-level information that is not disclosed to lower-level employees. In this case, a hybrid cloud gives more flexibility than a private cloud and more privacy and safety than a public cloud.


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## Benefits of the Cloud for Consumers

There are so many benefits of using cloud computing that it’s hard to even keep count—the possibilities seem as endless as the cloud itself! A few key features are:

- Businesses can **save money and manpower** by offloading hosting and maintaining a private server with a full IT support team

- Multiple people can view and access the same information via **instant file sharing**

- If a device breaks or a network crashes, **data is safely backed up** by the cloud

- **Instant communication** and coordinated real-time data of all resources

- All web applications, including social media, allow for **greater social circles**

- Users are no longer limited by the potential power of a single hard drive, and can instead wield the **extended power of a bigger CPU**

- Businesses that need to operate on-the-go have **location independence** while using the cloud, so they can still access all their resources

- Easily **scalable testing** for newly-built customized applications

- Installations and **updates are instantly applied** by the SaaS provider via the cloud instead of having to physically meet to ensure proper hardware compatibility

- Accessible processing power to help businesses **participate in industrial trends** like big data, Machine Learning, and Artificial Intelligence


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## Cloud Computing Benefits for Businesses

Because the cloud is so helpful for businesses as they fluctuate and scale with demand, there are several types of cloud-based solutions available:

### **Software** as a Service **(SaaS)**
- Application software that is sold or rented by a cloud service provider
 -  E.g. <a href="https://vksapp.com/products/enterprise">Enterprise Resource Planning Systems</a>, Salesforce, Dropbox

### **Platform** as a Service **(PaaS)**
- Infrastructure and development tools accessed through a virtual operating system (OS) called a *container* that is provided by a cloud service provider with a remote data center
 -  E.g. Microsoft Azure, AWS

### **Infrastructure** as a Service **(IaaS)**
- Infrastructure, physical and virtual servers, development tools, networking, and databases managed by a cloud service provider. This “backbone” of core computing tools is especially helpful for companies that need to adapt to spikes in scalability
 -  E.g. Applications created through infrastructural cloud-based tools

## Is Using the Cloud Risky or Dangerous?

Yes, and no. Like all technology with the potential for corruption, the cloud can be extremely vulnerable to targeted attacks. This is true of consumers as much as businesses. Consumers are at risk of their personal identifying information like credit cards and ID numbers being taken by hackers. Businesses, likewise, can be targets for competitors or hackers looking to sell high-clearance data. 

**All cloud data has the potential to be corrupted or stolen by malevolent actors.**

However, with proper attention to security measures, this is a risk **no different** than one introduced by other technological innovations. 

In other words, as long as you are prudent in setting up your cloud architecture, it is a better idea to employ cloud computing than not. 

There are downsides to the cloud, such as the necessity of an internet connection. In the same vein, if there are any outages or shutdowns at the level of the cloud service provider, you are out of luck until the cloud comes back online, so it helps to run a backup server for emergencies.


Cross-Training is an important management tool for both individual and team development. If you’ve ever worked at an understaffed business, you’re probably familiar with having to cover other coworkers’ responsibilities when they are absent or overloaded—*but there’s a better way!*

Cross-training as a business methodology has evolved far past the point where it was the equivalent of training all associates how to use the cash register when not restocking, for example. Developing employee skills in overlapping areas is best practice for ensuring interdepartmental flow.

Carefully planned cross-training scheduling standardizes flexibility within the workplace AND implements it in ways that help the overall bottom line and individual employee satisfaction. By using a few key tools and techniques, you can develop a highly adaptable, multiskilled workforce eager for any new challenge. 

This definition will take a look at the concept, including the benefits and disadvantages of cross-training as a principle, and then explore some practical tools from checklists to matrices.


## What is Cross-Training

### Business Methodologies That Use Cross-Training

Cross-training employees is a pretty universally-applied technique in the larger business world, but it is especially foundational to the following business and management methodologies:

- **Cellular Manufacturing** — a Lean Manufacturing subset that prioritizes quick production with as little waste as possible by grouping production cells or stations
- **Job Rotation** — the systematic movement of employees among departments to avoid burnout and redundancy from day to day
- **Agile Manufacturing** — a Lean methodology that focuses on fast customer response time within the production cycle
- **Just-in-Time Manufacturing** — a production model that employs pull cycles rather than push cycles in order to meet demand with little waste

Of course, while cross-training can be implemented alongside any other management system, these four methodologies have multiskilling at the foundational level, as they build upon a lean and efficient organizational approach around production cycle time.


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### Benefits of Cross-Training in the Workplace

There are so many benefits of cross-training employees that business leaders are continually finding new perks once developing employee capabilities and skills. Here are the most common benefits that come from cross-training in the workplace:

- **Lower costs** — by instilling your preferred skill sets into your current workforce and then promoting from within, you can save money otherwise spent on onboarding new hires

- **Adaptability** — a team with well-designed cross-training can adapt to changes in schedule or production more quickly because the required work falls under more than one person’s preview

- **Improve morale** — by recognizing the value in abstract problem-solving and uncommon solutions, you strengthen your team’s confidence in itself

- **Smoother workflow** — by focusing on the team’s success through individual attention, others will see the increase in communication and collaboration and do the same

- **Targeted opportunities** — identifying employees to promote for future managerial projects becomes easier because cross-training is a test run of their capabilities

- **Stronger collaboration** — your entire team’s interactions are strengthened because of a necessary increase in interdepartmental awareness as new skills are learned

- **Breeds motivation** — workers experience extended motivation between tasks because they can take breaks in-between activities

- **Better direct feedback** — a network of cross-skilled employees leads to more distributed, straightforward feedback about different types of tasks

- **Decreased absenteeism** — many businesses have reported that absenteeism decreases with cross-skilling plans, presumably since workers are more integrated with their work and driven to succeed

- **Scalable standardization** — with more than one person assigned to a skilled task, there is less chance of variability with a standardized SOP and it is likely a mistake will be quickly fixed

- **Flexibility** — if a team member is sick or suddenly absent, others can rearrange tasks and rotate responsibilities to seamlessly cover the gap

Training on the shop floor using digital work instructions

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### Disadvantages of Cross-Training in the Workplace

Overall, cross-training is a vastly successful and common practice. However, there are definitely some disadvantages to be aware of. Most of these disadvantages are swiftly resolved if the executives who are introducing the cross-training have done the necessary research and pre-planning.

- **Employee burnout** — be careful not to overload employees excited about cross-training with too much additional work aside from their other duties, as this could lead to stress and burnout, which is neither beneficial for the employee nor the employer who would have to hire a replacement.

- **Too many generalists** — this is akin to the problem of “too many cooks in the kitchen,” and this kitchen only has chefs—*no sous chefs or prep cooks!* In other words, you can’t train everyone to do everything, so when developing cross-functional skills, overlap responsibilities strategically. A team only works well when responsibilities are divided AND shared, instead of dropped for the first volunteer with an idea.

- **Mismatched compensation for added work** — at the very least, cross-training will add more work onto employees, so you must compensate your trainees appropriately. Whether that compensation is a pay raise or a title change or even a promotion in seniority, it will ensure that your employees don’t feel cheated for their extra efforts.

- **Confusion around responsibilities** — create a consistent system of passing off tasks as official responsibilities once trainees have completed their training, so that there is a clear division of workload and tasks don’t fall through the cracks.


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## How to Implement a Cross-Training Plan

Creating a cross-training regimen is straightforward, but it does involve a hefty amount of brainstorming. The principles behind a multiskilling management strategy are fairly easy to comprehend, but there are so many factors to keep in mind that without a proper visual planning checklist, you are bound to forget at least one or two. 

Fear not — the resources below will help you get organized.


### Pitfalls to Avoid When Cross-Training

At every major stage of the training process, return to this list of potential pitfalls to remind yourself of your goals and areas for improvement:

- **Know your team individually** — before implementing cross-training programs, you have to know your team members individually, including how they work best and which areas of niche knowledge they may hold. Some team members may excel at cumulative multitasking whereas others may learn best by powering through a couple training sessions

- **Uphold standardization** — ensure you’re not just passing around tribal knowledge, you’re standardizing it for future projects through SOPs

- **Decrease workloads strategically** — while training, workers will need a decrease in their routine tasks so they can concentrate on learning

- **Communicate growth** — clearly communicate that cross-training is NOT the first step of mass layoffs or downsizing

- **Recognize and reward value** — recognize the added investment of new skills in top-performing employees by giving promotions or higher compensation

- **Consider career trajectories** — consider development of your employees over a long-term time period. It wouldn’t make sense to cross-train a budding analyst in HR when they could be cross-trained in something more aligned with their career goals, like data architecture or structural coding

- **Be specific** — outline a specific learning schedule for all team members and keep track of progress to make sure no one feels lost

These bullet points are different from the checklist below because they aren’t ever really “checked off”, they are continuous improvement considerations as your cross-skilling plan develops over time. 



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### TOOLS IN PRACTICE: Cross-Training Planning Checklist

Okay, so now that you’ve finalized the goals of your cross-training plan, you need to keep an eye on all the details (and there are many to monitor!). Use this cross-training checklist to ensure you have done due diligence to the project’s guidelines, and check off each step as you complete it.



Cross-Training Checklist

A Training Needs Analysis (TNA) is a helpful tool for tracking the life cycle of a new training process in development. These analyses can vary greatly depending on the areas of focus, but tend to divide the work into four distinct steps.

1. **Identify business plan** — what you are trying to do and how
2. **Identify performance goals** — how you will measure success versus failure
3. **Identify skills gaps** — look at the skill sets you have to work with
4. **Establish new standardized solution** — implement cohesive process with checks & balances to ensure new controlled SOPs

These four steps can be further explored according to one’s unique business needs, so feel free to make it as detailed or sparse as you prefer, as long as the steps to success are broken down into the above four categories.



### TOOLS IN PRACTICE: Cross-Training Matrix Template

The best way to keep on top of your cross-training implementation is to track the results on a cross-training matrix. The template below is an example of one of these matrices.

You can create your own template using a grid like the one below, where the y axis column lists all of your employees, and the columns along the x axis refer to different skill sets needed in the workplace. As individuals grow in their skills and receive further training, their progress is marked in the chart for instant visual recognition of the intended goal.


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Let’s walk through this example cross-training matrix together:

- At first glance, it looks like Janet, having done excellent with her recent reports, is being trained to help lead a special project and to help with coding when it gets too overwhelming for Hank to do alone.
- Hank is deft at writing scripts and completing payroll, so he’s been given some direction about gathering info for reporting.
- Glen does payroll but he’s wanting to branch out, so he’s being trained for another special budgeting project in the accounting department.
- Finally, Mary has done lots of reporting, and in-between quarterly cycles, she has been helping out with back-end scripts and has just started to receive training for payroll.


Of course, templates are usually larger and more complex than this one, and you may need several different templates, some for tracking progress and others for scheduling meetings or training sessions, for example.

*Don’t forget to keep it simple.* The whole purpose of the matrix is a visual-at-a-glance. If you need to stuff more information into a matrix, then evaluate which constraints you need to measure and consider using several templates for respective tasks.

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Cross-training in the workplace is an effective management strategy that uses scheduling templates, matrices, and checklists to organize ongoing development.

## What is Cycle Time?

Cycle Time is defined as the time it takes to produce one item within the manufacturing environment. It includes any stalls or pauses that may occur intentionally or unintentionally during production. 

Knowing how long it takes to produce items enables companies to manage their resources in an intelligent and efficient way. Tracking a product’s Cycle Time gives manufacturers the ability to measure their productivity while efficiently allocating resources to optimize production flow. Whether using a <a href="https://vksapp.com/blog/push-vs-pull-manufacturing">push or pull manufacturing system</a>, Cycle Time is a key metric for your production schedule and time management. 


## When Does Cycle Time Start and End?

There is no hard and fast rule on how to measure Cycle Time. It depends on the company, the process, and the product. Some companies measure their times based on when they have the raw material inventory whereas others will begin to measure at the point of worker engagement. 

Others begin the clock as soon as a customer’s order has been made regardless of other factors -- a method that is useful if also calculating <a href="https://vksapp.com/dictionary/lead-time">Lead Time</a>.

That being said, the Cycle Time of a product typically begins at the initial commencement of work and ends at the final product release. The timer starts when materials, tools, and workers are in place and it continues until the product is complete and ready to leave the production area.

## Why Is Cycle Time Important?

A hands-on approach to time management has big implications on the resources used and the costs for the customer. Although time is not a physical good, it is useful for manufacturers to see time as a limited resource. 

**Wasted or unoptimized time is just as harmful as wasted materials.**

So it is beneficial to track how long a process takes and review the factors that affect it.

Tracking Cycle Time provides manufacturers with valuable insight and data into how their production is running. This data can be used to track productivity, fluctuations, improvements, and impediments to the production flow. Or it can be used to indicate if the production schedule is coinciding with demand (Takt Time).

In this way, Cycle Time is a valuable metric for both push and pull based manufacturing systems. Every manufacturing business is able to gain key insight into its operation. Offering a big perspective to help make wiser decisions.

## How to Calculate Cycle Time?

Calculating Cycle Time is fairly simple as all information is sourced from already completed work. You only need two pieces of data:

1. The total number of units produced (U)
2. The total available production time that was required to complete those units (TAPT)

Let’s put this into perspective: Imagine you produce high-quality wood baseball bats for kids. At the end of the first day of production, after your 5 workers have completed 30 combined hours of work (TPAT), 60 units of wood baseball bats (U) have been completed. Your Cycle Time (CT) would be calculated like this:

<p align="center"><strong>TAPT [30] / U [60] = CT [0.5]</strong></p>



Every half an hour (0.5 h), your employees produce 1 completed wooden bat. 

Simple enough, right? 

Depending on the product and the speed of production, some manufacturers measure Cycle Time by units per minute or even units per second. If you produce aluminum soft drink cans, you will most likely need to frame your cycle time differently than in our wood bat example as some aluminum processes can work at speeds close to 2000 cans per minute. 

## Takt Time vs. Cycle Time vs. Lead Time

For companies engaging in pull manufacturing, where the customer pulls the product onto the market, the usefulness of tacking your Cycle Time is paramount. This is especially true when comparing it to your Takt Time and Lead Time.

- <a href="https://vksapp.com/dictionary/takt-time">Takt Time</a>: The needed production time to keep up with demand.
- Cycle Time: The actual production time of one item. 
- <a href="https://vksapp.com/dictionary/lead-time">Lead Time</a>: The time from when the customer places the order to when they receive the order and payment is fulfilled.

As much as possible, your Cycle Time needs to match your Takt Time. If your Cycle Time is faster or slower than your Takt Time, then you are at risk of over or under-producing. As your demand fluctuates, your Cycle Time needs to be adjusted accordingly.

Although Lead Time does not need to match the other two metrics, it is an excellent way to track your customers’ experience. Once this is understood, you can find creative ways to get your Takt time, Cycle Time, and Lead Time working together. 


Cycle Time is defined as the time it takes to produce one item within the manufacturing environment. It includes any stalls or pauses that may occur intentionally or unintentionally during production. 

A Design Failure Mode Effects Analysis is an investigative summary of the potential risks during production that are identified in the design stage. From a history in aerospace engineering, FMEA applications now stretch from industries like software and manufacturing.



## History of DFMEA

Failure Modes and Effects Analyses were first used by <a href="https://vksapp.com/industries/aerospace">aerospace</a> engineers at NASA in the 1960s to track rocket prototypes. During the 1970s, FMEA became more popular in other industries, like US environmental and geological projects. 

Nowadays, FMEA is routinely used by quality, reliability, and safety engineering teams. The point of this process is to analyze an effects analysis in order to determine a failure mechanism – once a failure mechanism, or point of failure, has been identified, design modifications can be made to fix the errors before they are seen on the production room floor.

With a DFMEA in particular, the intended perspective is on design, and so the analysis must take place concurrently with the design and testing phases pre-production. 

There are 3 other types of FMEA:
- **FMECA** stands for Failure Mode Effects and Criticality Analysis, which divides the assessment into two measurements: failure and criticality of failure modes
- **PFMEA** adds “process” to the beginning of the acronym, representing a focus on assembly workflow, and is meant for the next step after design
- **Functional FMEA** is often used for software before the design stage has begun, and identifies the core requirements for design




Remember the Ford Pinto, the first North American subcompact car? After the 1980s, Ford Motor Company began using FMEA reports to ensure safe design for future models.

FMEA represented as a rainbow, 1. Effectiveness Analysis, 2. Team of Experts, 3. Data for Analysis, 4. Failures Effects Causes, 5. Asset Criticality Assessment, 6. Risk Mitigation Actions

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### Inductive vs Deductive Reasoning

An FMEA works using **inductive** – or forward – reasoning. This **top-down** approach works by making observations about a service or product and gradually drawing around a hypothesis to reach a final assessment.

The opposite to inductive reasoning is **deductive** reasoning, which is backward – or **bottom-up thinking**. This type of reasoning draws valid inferences and assembles these into a conclusion where the logic follows the premises.


## The 10 Steps in a DFMEA

There are ten steps of a DFMEA, and some of them seem repetitive, but are essential for uncovering minute potential failures. 

1. **Review design** – the assessment begins with an introductory critical overview
2. **Identify potential failure modes** – participants will mark areas where they suspect failures could occur, whether or not there is evidence of failure
3. **Identify potential failure effects** – the effects of certain mechanism failures can have far greater impact for use and safety than failures themselves, so these effects are anticipated in the report
4. **Identify potential causes of failure** – different than effects, pinpointing potential causes of that failure is a way of identifying a trigger or catalyst that may be the culprit of later problems
5. **Assign severity ranking** – A number from 1 (negligible effect) to 5 (catastrophic failure) is assigned, depending on the results of the type of failure and whether only parts of the product are damaged or rendered irreparable
6. **Assign occurrence (probability) ranking** – A number from 1 (extremely unlikely) to 5 (inevitable, frequent failure) is assigned to represent a range of the frequency of failures
7. **Assign detection ranking** – A number from 1 (certainty of fault detection) to 5 (undetected by operators) is assigned to indicate the probability that failures will be caught and corrected by real-time operators, and is helpful for assessing the maintainability of a production system
8. **Calculate Risk Priority Number (RPN)** – The RPN is calculated using the S, P, and D rankings above using the following formula:

RPN = Severity (of failure) × probability (of failure happening) × detection (the chance that the failure would go undetected before correction)

9. **Outline action plan** – at this stage, engineers will draw up a plan to correct the design risks in order to start testing their concluded hypothesis
10. **Recalculate RPN** – finally, the RPN is redone to see the anticipated impact of the changed design plan

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## Common DFMEA Applications

In almost any industry where quality is a key factor, a DFMEA can help with error prevention and greater control during assembly and production. Some of the applications of a DFMEA:
- Designing a new, independent product 
- Popularly used in total quality management (TQM) business philosophy
- For making product improvements to an underperforming product
- For re-designing a system of assembly or production
- For developing new product distribution and marketing strategies
- For saving costs on failure detection by pro

### DFMEA Industries

Any team wanting to assess their probable risk of failure in the production and delivery of a product or service can perform a DFMEA. They are most popularly done in the following industries:
- Manufacturing
- Software (SaaS)
- Healthcare
- Service Industries
Of course, the depth of a DFMEA will vary depending on the levels of error detection necessary, and some industries may more reliably use root-cause analyses or deductive reasoning strategies.

## Downsides of DFMEA

A DFMEA report is extremely unique depending on the product and the team assessing it. One of the biggest difficulties of any FMEA is that the failure may be identified, but it cannot be fixed until the failure *mechanism is also identified*. There is great risk for this minor difference to lead to errors of correlation and causation. 

Moreover, assigning numerical indicators to risk factors may help calculate an overall probability of failure, but may not be accurate enough in assessing the actual risk when there are concurrent failures. If there is more than one problem, then many versions of a DFMEA may be required as well as the more general <a href="https://vksapp.com/dictionary/root-cause-analysis">root-cause analysis (RCA)</a>.


A Design Failure Mode Effects Analysis is an investigative summary of the potential risks during production that are identified in the design stage. From a history in aerospace engineering, FMEA applications now stretch from industries like software and manufacturing.

## What is Downtime?

Downtime is defined as any period where production has stopped. The production is still costing money but no revenue is being generated. Within manufacturing, there are numerous causes of downtime such as machine breakdowns, workforce shortages, worker injuries, resource shortages, poor scheduling, and even planned downtime. 

Some instances of downtime can be controlled while others are inherently uncontrollable. Either way, this results in employees waiting which incurs costs without any return on investment. 

## The Idling Engine Analogy 

For a keen understanding of this concept within manufacturing, we can compare downtime to an idling car engine. 

When a car engine is idling, it is still consuming gas and developing wear and tear. But the car is not moving forward or performing the objective it is made for. 

Downtime works the same way. There are still costs that are incurred. In these periods, factors such as machine depreciation costs, employee wages, and energy bills still need to be paid. On top of this, there are often costs associated with getting an operation back on schedule. The longer downtime is extended, the larger the resource costs and the greater amount of time revenue is not being generated. 

From this analogy, we can see that downtime is wasteful on two levels.

1. **Consumes Resources**: Costs associated with having a facility that is not working. 
2. **Consumes Time**: This is time that could have been used to produce value but is instead left inactive. 

## The 3 Types of Downtime

### Planned Downtime

Planned Downtime happens when shut down intentionally. Most often, downtime is planned when certain actions can only be accomplished if the operation or process is not running. 

Although we normally see downtime as a negative outcome in manufacturing, it can also be a necessary evil. There are times when productions need to be paused to conduct meetings with employees, implement process improvements, and/or perform valuable maintenance. 

One key feature to note is that planned downtime costs significantly less than unplanned downtime. 

#### Example of Planned Downtime

Imagine you run an aluminum extrusion operation where heated aluminum is pushed through a die to produce the desired shape. One of your machines is scheduled for a complete maintenance call. The use of this machine will need to be stopped entirely for maintenance crews to perform the required actions. 

In this case, you adjust your operation so that this planned downtime creates the least amount of impact on the whole operation. Using <a href="https://vksapp.com/products">work instruction software</a>, you inform workers of the maintenance schedule and assign other machines within their work orders. Maintenance crews Lockout-Tagout the specified machine during low-volume periods and the operation barely feels the loss of time with the equipment. 


In the case of small repairs and basic maintenance, track who is qualified to perform these actions with our <a href="https://vksapp.com/blog/enhance-workforce-training">certification feature</a>. Strategically plan your workforce with the most accurate information. 

### Unplanned Downtime

Unplanned Downtime happens when an operation has been shut down outside of the control of the company's leaders. It is the result of machines, processes, or people being pushed beyond their capabilities to the point of producing accidents, breakdowns, and failures.

Other serious causal factors are also included within this category. Natural disasters, workforce strikes, and employee injuries all produce unplanned downtime in an operation. 

The cost of unplanned downtime is difficult to pin down due to the size and scope of every production. However, it is widely believed that unplanned downtime costs at least 10x more than planned downtime. 

#### Example of Unplanned Downtime

In a factory producing olive oil, numerous hydraulic machines cold-press the oil from the gathered olive seeds. But there's been a malfunction and now the press is leaking hydraulic oil all over the production floor. With the red slippery substance contaminating the production area, the operation is immediately shut down. 

Clean-up crews, maintenance workers, and quality inspectors will need to perform their key actions before production can begin again. Workers are either sent home or given other tasks in the meantime, resulting in workers waiting while not generating any revenue for the company.


Although a short period of time is devoted to starting and stopping equipment, many workplace accidents are concentrated to these times. With work instruction software, create detailed <a href="https://vksapp.com/blog/machine-setup-quality-performance">machine set up and shut down procedures</a> so that operators are always protected by following the right steps. 

### Idle Time

As we saw in our Idling Engine analogy, Idle Time still incurs costs while slowing down production and revenue. If departments of your operation are slower or faster than the production schedule, other departments are likely to be sitting idle. 

#### Example of Idle Time

Take for instance an LED billboard manufacturer. If billboards are assembled at a rate of 5 a day while quality teams can only check 2-3 per day, then there is a clog in the operation. This requires the assembly line to slow down production to mitigate bottlenecks, resulting in the assembly team waiting for quality teams to catch up. 

Did you know that Watchfire Signs, a leading LED Billboard manufacturer in the U.S., uses our work instruction software across their operation? See how they <a href="https://vksapp.com/case-studies/watchfire-signs">achieved their Goals in 1 Year by using VKS</a>. 



Downtime is defined as any period where production has stopped. The production is still costing money but no revenue is being generated. Within manufacturing, there are numerous causes of downtime such as machine breakdowns, workforce shortages, worker injuries, resource shortages, poor scheduling, and even planned downtime. 

## What is Enterprise Resource Planning (ERP)? 

Enterprise Resource Planning is software used to manage a company's resources such as material inventory, workforce, financials, and more through one intelligent hub. 

Enterprise Resource Planning can often be a bit difficult to define as ERP systems perform numerous company tasks, often performing the job or facilitating the responsibilities of an <a href="https://vksapp.com/dictionary/material-requirements-planning-mrp">MRP</a>, CMMS, PLM, and other business platforms. 

To put it simply, an ERP is a management software that enables all of a company's key departments to communicate efficiently in an automated and streamlined manner. This allows companies to enact resource planning through complete integration and connections between all processes and functions within the company. 


## How Does an ERP Work? 

ERPs unify the segmented approach to business operations. Under past industrial methods, each department was responsible for their own actions and information. While the information was shared between departments, it was accomplished through manual processes that were slow and inaccurate. 

The modern ERP connects company departments and allows the whole business to communicate quickly and efficiently. Enterprise resource planning will integrate essential departments into one cohesive resource management system.

<img src="https://strapi.vksapp.com/uploads/ERP_1f57f05d55.jpg" alt="Precedence Diagram" className="center">

Each of these departments creates and stores data for internal use. But what if you want to share purchasing data with finance, or inventory data with manufacturing? 

An ERP works to connect each of these departments through their individual systems and actions, essentially making ERPs the glue that holds these disparate company systems together. Without an ERP, it takes a lot of manual processes to get information from one department system to another. 

For example, let's take a manufacturing company that produces high-end keyboards of all shapes and sizes. Before ERP implementation, the manufacturing department would have received work orders through manual processes conducted by work order management. Retailers make an order for a shipment of ortholinear keyboards and the order is manually transmitted to warehousing and manufacturing departments.

Similarly, the manufacturing department would manually communicate with the warehousing department and the inventory software they use, asking: 

- How much stock do we have? 
- How much final product do we have? Etc. 

With an ERP, all of these processes become automated. Information from every department is funneled through the ERP, meaning that users don’t have to access each department’s system or talk to department representatives to gather the information they need. The data is now accessible through one central location. Likewise, as sales are made and customer orders are placed, work orders can automatically be pushed directly to the manufacturing department in real-time. 

Real-time information sharing, provided by the ERP and other systems creates an impressive and responsive environment. 

Once an ERP has been integrated into their operation, inventory usage data is automatically sent and received between their <a href="https://vksapp.com/products/enterprise">manufacturing execution system</a> and their ERP. While following the specified process, the work instruction software is sending part usage and tracking data to the ERP through the <a href="https://vksapp.com/dictionary/application-programming-interface">API</a>. 

Now, the company is gaining real-time tracking data on every used and unused part within their facility.

Similarly, quality data, collected by a company’s <a href="https://vksapp.com/work-instruction-software">work instruction software</a> is automatically sent to the ERP where quality control departments can track the specific PLM (Product Lifecycle Management) data alongside their <a href="https://vksapp.com/blog/edhr-medical-device-manufacturing">eDHRs (electronic Device History Records)</a>.

## The Advantages and Disadvantages of Enterprise Resource Planning

### ERP Advantages

ERPs have some considerable advantages for modern businesses wanting to streamline and automate their internal information sharing and interdepartmental processes. 

- **Streamlined organization**: By gathering data from all corners of a business and making it accessible through one intelligent hub, departments are able to quickly pull up the data they need at any moment. This enables quick and effective decisions to be made. 
- **Accurate reporting**: Systems without a central ERP will have various sources of data and manual processes that are susceptible to errors and inaccurate analysis. However, with an ERP, reporting is a data-driven process that has little room for miscommunication due to its streamlined automated processes.
- **Collaboration-based work environment**: With access to interdepartmental information, the whole workforce is brought together as one team working together for the same company objectives. 
- **Reduced operational costs**: Despite the high price point of an ERP, there is a considerable return on investment. Each of the preceding advantages enables companies to mitigate waste and cut costs considerably. 

### ERP Disadvantages

Despite the widespread popularity of ERPs within the manufacturing sector, some downsides still lead people to describe ERPs as a “love-hate relationship”. One user even compared an ERP to a marriage by saying: “In good times and in bad, in sickness and in health”. 

This is due to a few reasons:

- **Long implementation times**: This is primarily because the implementation of an ERP system is lengthy to say the least, often taking upwards of 9 months to get it up and running. 
-** Takes time to customize**: After the implementation time, it could take longer to get it running specifically in the way you need. 
- **The systems are expensive**: ERPs can range anywhere from $150,000 - $750,000 per year for small to medium-sized businesses. 

Unlike ERPs, <a href="https://vksapp.com/work-instruction-software">work instruction software</a> is quick to establish within your operation. Instead of implementation taking a few months to a year, VKS can be up and running in a matter of days. If you have an already established ERP running in your business, VKS will quickly integrate with your current business goals and ERP platform. 

## ERP Recommendations

There is no one ERP brand or provider that we’ll recommend over others. This choice is entirely up to you and the needs of your business. But here are 5 things that every manufacturer should look for in an ERP. 

1. It should have a strong focus on automated actions to reduce dependence on user expertise.
2. It needs to be scalable and flexible as your company grows and the market shifts. 
3. An ERP should be accessible from any device. Make sure the information is available on computers, tablets, and mobile devices. 
4. It should easily integrate with other production systems such as work instruction software and MES platforms. This will improve the capabilities of the company and the information gathered by the ERP. 
5. Information should be easily collected and stored while also providing methods for data analysis and research. 

If you want to speak to an industry specialist to learn more about how VKS can enhance the potential of your existing or future ERP, <a href="https://vksapp.com/book-demo">book a demo today</a>. 


Enterprise Resource Planning (ERP) is a management software that enables all of a company's key departments to communicate efficiently in an automated and streamlined manner. This allows companies to enact resource planning through complete integration and connections between all processes and functions within the company. 


## What is a Flexible Manufacturing System (FMS)? 


A flexible manufacturing system is a methodology that enables companies to be flexible in the face of changes like market demand, manufacturing challenges, or opportunities for innovation. Whether these changes are predictable or not, FMS companies quickly shift their production to meet the needs of their business and the market. 

Typically, FMS involves organizing and connecting workstations with a central computer that manages and tracks the production process while feeding materials and data to the production line/machines. While the system enables manufacturers to fully automate their system while maintaining production flexibility, two of the main disadvantages are that it is extremely complex and expensive to set up. 

Although FMS is predominantly a systematic approach to manufacturing, it is also a philosophy that companies can apply to their own operations without spending a dime.


## What Does Flexible Mean Within FMS? 

Within the context of manufacturing, flexibility refers to the ability to change aspects of a production line based on market requirements and production environments. 

For example, mass production environments are naturally rigid since customers have come to expect little product variation from them. Although, even mass production environments benefit from flexible practices that affect volume and delivery. On the other hand, companies that are involved in mixed-model manufacturing or <a href="https://vksapp.com/blog/mts-mto-ato-how-you-can-use-these-strategies">ATO/MTO environments</a> require greater levels of flexibility so that change can be quickly enacted based on external factors like:

- The market demand;
- Resource availability;
- Workforce ability. 

### 4 Types of Flexibility

1. **Volume Flexibility** is the ability to change and adjust production volumes. This enables companies to adjust resources and times without negatively impacting their ROI. 
 
2. **Mix Flexibility** is the ability to produce a wide range of products or <a href="https://vksapp.com/blog/dynamic-work-instructions">variations of the same product</a>. This allows companies to respond quickly to respond to market demand. 

3. **Manufacturing Flexibility** is the ability to control production despite the normal uncertainties of manufacturing. Despite changes and unforeseen issues, the production recovers and adapts to the required resources and workforce requirements.

4. **Delivery Flexibility** is the ability for customers to set their desired delivery dates and <a href="https://vksapp.com/dictionary/lead-time">lead times</a>.

For each of these flexibility types to work, there is a certain measure of flexible practices that need to be integrated directly into the production system. This can be done with automated process lines, connected machines, and/or advanced <a href="https://vksapp.com/blog/autonomous-smart-work-instructions">smart manufacturing systems</a> like VKS. 

## How Does FMS Work? 

For any system or operation to be flexible, it needs to be connected. There need to be strong lines of communication that facilitate collaboration between production segments. Otherwise, the system will break as the segments work independently. 

For FMS environments, 3 core elements bind the whole system together:

1. **Work Machines**: These are the machines that perform the physical work. Includes material presses, CNC machines, etc. 

2. **Material Handling System**: This system keeps a steady flow of materials for the work machines. This can be automated by machines and/or tracked and managed by material handler personnel  

3. **Central Control Computer**: This is the brain of the operation, managing material movements, machine flow, required pieces, and more. 

As machines perform the work, materials are constantly flowing to maintain a steady and theoretically unending flow. The central control computer is managing quantities while also tracking key production data and machine/process health information. 

### Example of Flexible Management System

Imagine you have just received a large contract to fabricate a wide variety of construction bolts and screws. You’ll need to fabricate drywall screws, steel screws, chrome-plated bolts, copper bolts, and more. 

There’s only one issue: You don't have the space nor the required amount of dedicated machines to create each bolt/screw variant. Plus, you don't have enough staff to run this operation 24/7, which is what you will need to meet your contract. 

Luckily, you have figured this out already and have some time to prepare a Flexible Manufacturing System. You set up your CNC machines to begin creating the steel construction screws. Steel is loaded into the machine automatically from your inventory by the material handling system. Once the CNC machine completes the required amount of steel screws, it will automatically send a message to the central control computer asking to begin producing a new product - in our case, copper bolts. The material handling system loads the CNC machine with copper and the operation is quickly producing the required copper bolts. 

Changeover between products is fast and simple. If you multiply this over several machines, production is virtually unstoppable. The only con is that setting up this type of system comes with some hefty upfront costs.

## How to Make Any Production Line Flexible

If you don’t have an automated production system and material handler machines, or if your production doesn’t fit a complex fully automated system, there are still ways for you to take the best parts of FMS and apply them to your operation. 

As we covered, FMS is a system and a philosophy that hinges its success on strong connections between production segments. If we apply this to a manual process (with some <a href="https://vksapp.com/products/enterprise">Industry 4.0 innovation</a>), we can achieve the same, if not better, results. 

Each production relies on people. Using tools like our <a href="https://vksapp.com/work-instruction-software">work instruction software</a> enables your workers to seamlessly communicate with their teams, machines, and systems. Despite shifts in market demand or production challenges, VKS opens the doorway for manufacturers of all types to apply smart, flexible, and fast-acting practices to their operations. 


A flexible manufacturing system is a methodology that enables companies to be flexible in the face of changes like market demand, manufacturing challenges, or opportunities for innovation. Whether these changes are predictable or not, FMS companies quickly shift their production to meet the needs of their business and the market. 

## What is a Guidebook?

The definition of a guidebook can be hard to pin down for multiple reasons. Is it a work instruction....yes. Is it a standardized process....yes. Is it a training document...yes. Is it preventative maintenance....yes. Is it an advanced system that engages workers while gathering data and connecting to other systems and tools… YES!

A simple definition might be: guidebooks are instructions that guide workers on the best way to perform a task in a step-by-step format. They guide workers through their tasks and responsibilities. 

But we’ll need more than this to get a complete picture of what a guidebook is and what it does for various industries

VKS guidebooks go beyond just a step-by-step process. They are the next evolutionary step to standardizing and managing your operation. With an intelligent digital interface that provides quick and easy information, connects with other systems/tools, and monitors valuable production data, guidebooks provide strong methods for empowering your workers and optimizing your operation. 

In situations where processes and procedures are at risk of damage if workers deviate from the established procedure, work instructions provide stability and security on the shop floor. 



<img src="https://strapi.vksapp.com/uploads/assembly_tablet_f1cdef87f4.png" alt="guidebook" className="center">

## Guidebooks Tackle the “How” of Any Process

Work teams within an operation understand the core elements of their job. 

They know what needs to be done.
They know who will perform the job.
And they know when it needs to be done.

What they’re explicitly missing is HOW their job needs to be performed.

And if an operation relies on mixed-model assembly or anything resembling MTO/ATO environments, then workers may not consistently be performing the same work, leading to confusion between processes. 

Guidebooks solve this problem by giving operators clear instructions that lead them through each task.

On top of this, guidebooks also gather data every time they are used. Either through autonomously gathering production data in the background or through direct employee engagement, guidebooks provide complete visibility into every process on a shop floor. 

## 2 Guidebook Examples

Guidebooks are used to instruct workers through any process, making them a versatile tool within any industry. From providing detailed instructions on how to create, fabricate, assemble, and clean, to training new employees and troubleshooting advanced issues, VKS guidebooks enable companies to take control of their processes, repeat success, and mitigate errors. 

We won’t be able to go through a complete list of <a href="https://vksapp.com/case-studies">use cases</a> but we can present some key characteristics using 2 examples. 

### Example 1: Dynamic Toy Assembly

Put yourself in the shoes of an operator for a custom toy car manufacturer. Every day you receive numerous work orders for different toy cars to be assembled. The cars use relatively the same components but there are some differences between each custom car based on the demands of the customers. 

Here lies the problem: You need to keep track of each order and build the right car according to specifications and demand. But as the procedure and components change for every car, it can be hard to keep track of which specifications to apply to each product. 

Luckily, you have a dynamic Guidebook that has been written for this process. 

As each specific work order is assigned to your station, the Guidebook displays the right instructions for each build. No matter if the customer wants a custom cherry red hood or a banana yellow chassis, the right work instructions are displayed every time. 

This means that with detailed instructions that change based on product demand, you and your team members always perform the right job at the right time.

Plus, while you are working, the guidebooks are capturing valuable production data autonomously in the background.


Dynamic processes enable businesses to boost productivity. More so, it enables them to efficiently cut down on inventory and pursue a <a href="https://vksapp.com/blog/push-vs-pull-manufacturing">Pull Manufacturing System</a>.

### Example 2: Optimization and Quality Control

Aside from standardizing your manufacturing operation, guidebooks enable you to gain greater control of your entire operation through advanced knowledge channels. Let me explain. 

Let’s go back to our toy car example, but we’ll situate you as manager on the shop floor this time. Productivity is up, thanks in part to the dynamic standardization of guidebooks. But now you want to optimize your operation even further by boosting production times.

For this, you need to look at the data collected from your guidebooks. You've already connected VKS to your other manufacturing systems so valuable data is pouring in every time a Guidebook is used. 

Adding to this, your workers are also able to provide their unique feedback when they are working through the interactive Guidebook interface and <a href="https://vksapp.com/dictionary/smart-forms">smart forms</a>. 

Guidebooks are the foundation of the <a href="https://vksapp.com/blog/best-mes-software">worker-centric MES</a>. They enable manufacturers to gain key information that can only be captured by people performing the process. At the same time, they are also driving visibility from your other systems. 

Coming back to our scenario, with the immense source of data coming from the guidebooks, you are able to see which factors aid your productivity and which ones don’t. This enables you to optimize and gain better control of your production processes. 


Any process can be standardized. And standardization is enhanced by digital technologies. Check out these <a href="https://vksapp.com/blog/top-15-standard-work-instruction-examples">Top 15 Standard Work Instruction Examples</a>.

## Who Writes the Guidebooks?

You do! Well, maybe not you in particular, but people within your company do. Often engineers, experienced operators, and even sometimes managers will be responsible for creating standardized processes with digital guidebooks.

But there is one important thing to remember: Guidebooks and standardization are not always established by one person. You want the combined experience and knowledge of all your employees. 

This is a Guidebook's greatest asset. 

Every company has accumulated tribal knowledge within its workforce. The problem is that this <a href="https://vksapp.com/blog/how-to-retain-employee-knowledge">knowledge is often walking out your door</a>. VKS guidebooks allow you to gather the best practices of your most experienced employees and distribute them to all of your employees. This creates an environment where every worker has access to years of experience and knowledge. 

VKS guidebooks enable manufacturers to digitally enhance by combining intelligent software and the knowledge of their employees. When companies effectively put these two resources together, the possibilities are limitless. 

<div className="quote">
<p align="center" style="font-size:150%"> If you’d like more information or want to take a deeper dive into how <strong>VKS guidebooks</strong> can benefit your unique operation, <a href="https://vksapp.com/book-demo">book a demo</a> today! Taking control of your operation is only a click away.</p>
</div>


Guidebooks are the next evolutionary step to standardizing and managing your operation. With an intelligent digital interface that provides quick and easy information, connects with other systems/tools, and monitors valuable production data, guidebooks provide strong methods for empowering your workers and optimizing your operation

## What are the ISO 9000 Standards?

The ISO 9000 standards are a group of voluntary Quality Management Systems (QMS) created by the International Organization for Standardization (ISO). The standards are created and maintained by professionals from all over the world dedicated to creating efficient and continuously improving quality standards for manufacturing and other organizations. 

ISO 9000 helps companies document and administer an effective QMS that spans an organization’s entire operation. This QMS enables companies to oversee their operations and ensure through detailed documentation that their company is compliant with a baseline standard of excellence. 


### A Little History About the ISO

You may have seen that the acronym ISO does not match its English title “International Organization for Standardization”. This is because the acronym would change in different languages, such as OIN in French. 

To standardize their name across many languages and regions, they chose to name themselves ISO which is derived from the Greek word “isos”, meaning equal. So in every language, their name is standardized as ISO. 

## Breaking Down the 4 ISO 9000 Standards

<img src="https://strapi.vksapp.com/uploads/e_DHR_tracking_list_b1fbc73d3a.jpg" alt="ISO 9000" className="right">

ISO 9000 can get a little tricky to understand. We have the coveted ISO 9001 certification but the other documents and standards provide useful information and tools for companies looking to become certified. 

Perhaps a helpful way of looking at it is that ISO 9001 consists of the requirements and action items to gain certification. The other standards lay out key terminology and provide a foundation for continuous improvement and auditing procedures. 

ISO 9000 currently consists of 4 QMS standards.

### 1. ISO 9000 - Vocabulary and Concepts

This standard outlines the fundamentals of Quality Management Systems and provides a structure for the other QMS standards within the ISO 9000 standards. 

Users gain a foundational understanding of key concepts, principles, and vocabulary that enables them to effectively integrate a QMS within their operation. 

### 2. ISO 9001 - QMS Requirements

ISO 9001 is the actionable portion of the ISO 9000 standards. It outlines the requirements that companies will need to comply with if they desire to become certified. 

The two main requirements are: 

1. Consistently demonstrate the ability to deliver products and services that fulfill consumer requirements while also adhering to the laws and regulatory requirements of the state. 
2. Enhances and improves customer satisfaction through effective QMS implementation. This includes improvement of systems and verification of QMS compliance. 

These criteria are designed to be general so that businesses of any size and purpose may adopt a QMS that fulfills their individual needs while still complying with ISO 9001 guidelines.

### 3. ISO 9004 - Continuous Improvement

This standard provides guidelines for companies to achieve success over time.  Or in other words, this standard is concerned with the implementation of continuous improvement that enables companies to sustain continuous growth. 

It also provides a self-assessment tool that enables businesses to review their adoption of continuous improvement standards found in ISO 9004. 

### 4. ISO 19011 - Auditing

ISO 19011 stipulates the guidelines for auditing Quality Management Systems. This is useful for organizations that wish to do a self-assessment of their operations as well as those performing a third-party assessment for other companies. 

 The quality standard document details:

- The principles of auditing;
- How to manage and audit;
- And how to select competent people for the audit process. 

Companies pursue ISO 9001 certification to increase their quality output and to display their commitment to quality management and their stakeholders. Although, some companies will opt out of the certification due to its bureaucracy. Here are some <a href="https://vksapp.com/blog/is-iso-9001-worth-it">pros and cons of pursuing ISO 9001</a>.

## Who Are The ISO 9000 Standards For?

At first, it was specifically geared toward manufacturers. ISO 9000 series of standards were created by ISO to help manufacturers implement standardized quality systems and maintain an efficient mode of operation.

But progressively over the years, the standards have expanded outside of the manufacturing sphere, such as transportation, construction, healthcare, hospitality, and technology. Adding to this, although the concepts, terminology, and requirements are highly regulated, the quality standards themselves are somewhat dependent on the company and industry. Different industries will have a distinct understanding of the quality standards most suited for their customers and other stakeholders. 

However, no matter the industry, all companies are encouraged to focus on the <a href="https://vksapp.com/blog/the-7-principles-of-total-quality-management">7 principles of Total Quality Management</a>. These principles are also mandated by the ISO. 

1. Customer Focus
2. Leadership
3. Engagement of People
4. Process Approach
5. Improvement
6. Evidence-Based Decision-Making
7. Relationship Management

## The Evolution and Revisions of ISO 9000 

ISO 9000 series of quality standards were first published in 1987 by the ISO as a minimum standard for quality output and operational performance. They first gained popularity in Europe and then a few years later, moved to North America. 

Now, the ISO draws from professionals from all over the world and is constantly evolving. Since 1987, the ISO 9000 series of quality standards has gone through a series of revisions. This is to account for modern practices and meet the evolving needs and understanding of quality across the industry. In this way, ISO 9000 is constantly keeping up to date with current practices and quality methods, essentially enacting continuous improvement on its own standards.

## How Do You Get ISO 9000 Certified?

Interestingly, the ISO does not directly evaluate if companies are complying with their Quality Management Systems. Rather, businesses seeking accreditation will need to reach out to third-party companies that have authorization to audit and award companies with the certification. 

Companies seeking to become certified need to first implement the recommendations within ISO 9000. Once this is done, the company would then need an audit to evaluate and confirm its compliance with the standards. This can be done internally or by an external company. However, only an authorized external company can issue the certification. 

Although the ISO does not perform the certification themselves, their website gives extensive information about <a href="https://www.iso.org/certification.html" target=”_blank”>selecting a certification body</a>. 



The ISO 9000 standards are a group of voluntary Quality Management Systems created by the International Organization for Standardization (ISO).  ISO 9000 helps companies document and administer effective methods that enable companies to oversee their operations and ensure through detailed documentation that their company is compliant with a baseline standard of excellence. 


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