The 5M+E model is a management classification system for exploring <a href="https://vksapp.com/dictionary/root-cause-analysis">root causes analysis</a>. Also known by other variations, 5M+E represents the factors involved in cause and effect troubleshooting: mankind, machine, materials, method, measurement, and environment.


Key Takeaways

## The Origins of 5M+E

5M+E first originated as a method called 5M, which was developed by T.P. Wright for aeronautical engineering. He developed something called the “man-machine-environment” triad, which is shown below. 



medium_The_5M_model_used_for_trouble-shooting.png

small_The_5M_model_used_for_trouble-shooting.png

thumbnail_The_5M_model_used_for_trouble-shooting.png

The_5M_model_used_for_trouble-shooting.png

The interlocking circles represent a holistic management approach to aviation safety. Wright’s model included 5 Ms:
- **Man**: the psychology and working habits of the people involved;
- **Machine**: physical requirements and conditions of tools and their working parts;
- **Medium**: environmental conditions affecting the experiment;
- **Mission**: reasons for combining the above elements;
- **Management**: leadership conditions outlining the governance of the experiment.

While Mission is at the heart of the method, Management is the largest circle and is meant to embody all of the other factors.

The 5M model was developed by Wright while he was at Cornell University during the mid-20th Century, and like many other management methodologies, has evolved greatly since then. Nonetheless, it is a useful tool for delving deeper into a root cause analysis or <a href="https://vksapp.com/dictionary/ishikawa-fishbone-diagram">Ishikawa diagram</a>.

*How is 5M+E a tool?* you may ask.

It’s a framework that you can use to supplement other tools. For example, in an Ishikawa diagram, your categories of contributing factors within the diagram could be the Ms in 5M+E.

When brainstorming issues and potential solutions, you can think of each M one by one, grouping similar issues together. For example, issues like “high absenteeism” and “digital skills gaps” can be placed within the M that stands for “Manpower,” while issues like “equipment failures” and “replacement parts ordering” can be placed under M for “Machinery.”




## The 6 Components of 5M+E

There are 6 parts of the 5M+E model which contribute varying viewpoints towards problem-solving. The model to which we are referring is specific to the manufacturing industry.

There’s no right or wrong way to go about using 5M+E – it’s meant to be a holistic approach to identifying the broader environment of certain individual factors. After grouping factors of interest into their respective M categories, it’s easier to see which broader areas of production need improvements or tweaks.

### 1. Mankind
Mankind involves the people who are working within the problem. In manufacturing, this includes shop floor and assembly workers, managers, shippers and distributors, customers, and anyone else who may contribute or be affected. 

### 2. Machine
Machine refers to the machinery involved in the manufacturing process as well as the conditions of using machine elements. This includes wear and tear, possible breakdowns, and other physical limitations posed by the equipment.

### 3. Materials
Materials refers to the actual product being fed into the machinery and processed for sale or further use. It may range from raw materials to components to finished products sitting in inventory.

### 4. Method
Method means the style of workflow in motion, whether driven by lean principles in a broad sense or type of production in a specific sense (such as <a href="https://vksapp.com/dictionary/batch-production">batch</a> or <a href="https://vksapp.com/dictionary/continuous-flow-manufacturing">continuous flow</a> production). Overall, it identifies the means by which <a href="https://vksapp.com/dictionary/value-stream-mapping-vsm">value is added throughout the manufacturing process</a>.

### 5. Measurement
Measurement refers to the means of assessing success or acceptable quality in product or performance. In general this could be standard units of measurement like meters or pounds. In manufacturing in particular, this is expanded to include <a href="https://vksapp.com/dictionary/key-performance-indicator-kpi">KPIs</a> such as <a href="https://vksapp.com/dictionary/cycle-time">cycle time</a> or other productivity metrics.

### 6. Environment
We prefer using “environment” rather than “mother nature” because it can intuitively also apply to the “environment” of the factory as well as the weather and climate conditions of the place of production. This includes factors like humidity, temperature, pressure, and other place issues like scheduling.

## Variations of 5M+E (Also Known As…)

The 5M+E model has been around a long time, and so many people have adopted the method for different usage purposes. Therefore there are quite a few variations that differ depending on the industry or the type of problem-solving undertaken.

The key thing to remember is that while there may be small differences between models, all have approximately the same purpose and work equally well for root cause analysis.

Some of the variations of 5M+E are:
- **6Ms** – this version replaces the E for environment with M for either Milieu or Mother Nature, depending on the use case. Some prefer 6Ms rather than 5M+E because it is simpler to say
- **5M+P** – this version replaces “man” with “people” for a more gender-inclusive perspective
- **8Ms** – this version expands the traditional 5Ms by including Management and Mission (present in Wright’s original diagram) as well as an additional M for Maintenance. Companies may refer to this model if there are major contributing factors to be addressed within management or company mission.
- **Different 5Ms** – finally, there are several versions that still go by “5M” that swap some categories for other M words. Some examples include foregoing Machine or Environment and instead using categories like Markets and Money. For example, a financial root cause analysis may include the category of “Money,” where relevant financial market projections are considered. 

Essentially, since 5M+E is a guiding framework for brainstorming in root cause analysis, it doesn’t matter too much which version you use, as long as it is robust enough to cover the landscape of your production processes. 




The 5M+E model is a management classification system for exploring root causes analysis. Also known by other variations, 5M+E represents the factors involved in cause and effect troubleshooting: mankind, machine, materials, method, measurement, and environment.


## 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 <a href="https://vksapp.com/dictionary/personal-protective-equipment-ppe">PPE requirements</a>
- 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/products/lite">work instruction software</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.

## 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.



thumbnail_binderjetting.jpg

binderjetting.jpg

### 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.

small_DED.jpg

thumbnail_DED.jpg

DED.jpg

### 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.



large_Prusa_i3_3D_Printer_-_Reprap_-_Completed.jpg

medium_Prusa_i3_3D_Printer_-_Reprap_-_Completed.jpg

small_Prusa_i3_3D_Printer_-_Reprap_-_Completed.jpg

thumbnail_Prusa_i3_3D_Printer_-_Reprap_-_Completed.jpg

Prusa_i3_3D_Printer_-_Reprap_-_Completed.jpg

### 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.


thumbnail_powderbedfusion.png

powderbedfusion.png

### 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.


medium_sheetlamination2.png

small_sheetlamination2.png

thumbnail_sheetlamination2.png

sheetlamination2.png

### 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.



small_stereolithography.jpg

thumbnail_stereolithography.jpg

stereolithography.jpg

### 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.

small_material jetting.png

thumbnail_material jetting.png

material jetting.png

## 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.

large_Iterative development.jpg

medium_Iterative development.jpg

small_Iterative development.jpg

thumbnail_Iterative development.jpg

Iterative development.jpg

### 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 intended 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. 

large_Waiter example.png

medium_Waiter example.png

small_Waiter example.png

thumbnail_Waiter example.png

Waiter example.png

## 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. 



large_VKS API.png

medium_VKS API.png

small_VKS API.png

thumbnail_VKS API.png

VKS API.png

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 is Business Intelligence (BI) Software? 

Business Intelligence software is a tool that transforms unstructured data into structured knowledge and insight. Primarily, BI software is used to collect, manage, and analyze the data generated by multiple systems within a business. With this tool, companies can centralize their data collection and make the most of the information they receive.

BI software is a broad term that is used all over the landscape of modern business. With so many uses from retail, to manufacturing, it can be hard to pin down any one definition. However, all BI applications have 2 things in common. 

1. BI software aims to efficiently collect and centralize data generated by a business.
2. BI software takes this data and transforms it into actionable knowledge that companies can use to direct and steer toward their goals.

All BI software achieves these two actions but between the software provider, the particular industry, and the exact needs of the company, there can be a lot of differences. For this definition, we will look at BI software and its application for a manufacturing setting 


## An Explanation of BI Software

From a user perspective, BI software functions similarly to a computer’s operating system such as Windows, macOS, or Linux. Without an operating system, your computer’s user interface would be limited to a sequence of 1s and 0s. These numbers would be hard to understand, let alone extrapolate any workable knowledge from them. 

<img src="https://strapi.vksapp.com/uploads/BI_49295af306.jpg" alt="BI" className="right">

Similarly, BI software takes the immense amounts of data generated by the shop floor and presents it visually so that almost anyone can understand it. Through spreadsheets, graphs, filtered tables, and charts, BI software takes the immense amount of data you generate and turns it into workable knowledge. 

For example, imagine your company produces a very popular brand of spatulas. Your employees use work instruction software to monitor and maintain the production line while your <a href="https://vksapp.com/dictionary/enterprise-resource-planning-erp">ERP</a> tracks inventory usage, <a href="https://vksapp.com/dictionary/downtime">machine downtime</a>, finance metrics, and workforce hours.

You’ve noticed that workforce hours are higher this year than last but sales have remained steady. You need to find the <a href="https://vksapp.com/dictionary/root-cause-analysis">root cause</a> of this increase quickly. Luckily, you have two systems that collect the data but you’ll need to cross-reference them. 

Using BI software, you take the unstructured data and create a structured timeline and spreadsheet. With this new visualized information, you find the root cause of the issue and quickly adjust certain elements of production to safeguard from higher than normal workforce hours. 

Companies use BI software in situations like these and many others to track performance across their departments and see trends develop over time. However, BI software needs intelligent programs to feed data. And the smarter the software, the stronger your business intelligence actions become. 

## Quality In, Quality Out

Have you heard the expression: “Garbage in, garbage out”? 

When it comes to collecting data, nothing is more true. If companies receive inaccurate data from their systems, then they have no foundation to make smart and informed decisions. Likewise, BI software will misrepresent the facts if it does not receive accurate data from a reliable source.

But if companies collect accurate data, they can take this information and turn it into effective actions. Systems like digital work instructions gather data from every action that is taken by your employees on the shop floor. This <a href="https://vksapp.com/blog/best-mes-software">worker-centric MES</a> collects performance data, completion times, quality control/assurance information, and data from any action performed by an employee. This level of data collection makes it one of the most effective data generation tools in the industry. 

<img src="https://strapi.vksapp.com/uploads/quality_data_36d6daaa36.jpg" alt="BI integration" className="center">

Once companies have a reliable source of data, they can funnel all the information to their BI software. 

To understand how data is gathered and then transformed by BI software, there are 3 linear steps. 

1. **Collection**: Companies collect data from their various systems such as maintenance software, ERPs, or digital work instruction solutions. 
2. **Organization & Analysis**: The data now needs to be understood. BI software analyzes the data and organizes it into categories that make it easier to understand and decipher. 
3. **Transformation & Reporting**: This is where BI software takes the analyzed and organized data and transforms it into readable reports like charts and spreadsheets. 

## 4 Types of BI Tools

Since BI software is an expansive application with various purposes and directives, the software can often come in many different shapes and sizes with a wide variety of tools for manufacturers to use. Let’s explore the common yet powerful tools of BI software.

<img src="https://strapi.vksapp.com/uploads/dashboard_8c8a4e1bab.jpg" alt="BI dashboard" className="right">

1. **Spreadsheets**: Due to the relatively inexpensive availability of software like Microsoft Excel and Google Sheets, spreadsheet programs are the most common BI tool. Companies can manually or automatically filter data into their spreadsheets to see various KPIs together. 
2. **Reports**: Similar to how spreadsheets organize and filter data, this BI tool is used specifically to generate reports automatically as the information is collected in real-time. 
3. **Visuals**: To help users quickly understand the implications of the generated data, visualization tools take the data that has been organized and create easy-to-read charts and diagrams. A good example of a visual chart useful to manufacturers is the <a href="https://vksapp.com/blog/best-mes-software">Pareto Chart</a>. 
4. **Mining**: Here’s where we get into the advanced capabilities of BI software. BI mining tools use AI (Artificial Intelligence), machine learning, and statistical analysis to find trends and patterns that could be overlooked if simply looking at the data at disjointed times. 

What’s great for manufacturers is that you don’t have to settle on 4 different systems to experience the benefits of these tools. Modern BI software now supports these various uses and is built specifically for companies to gain the best knowledge and insight from their data. 


Business Intelligence software is a tool that transforms unstructured data into structured knowledge and insight. Primarily, BI software is used to collect, manage, and analyze the data generated by multiple systems within a business. With this tool, companies can centralize their data collection and make the most of the information they receive.

Batch production is the means by which most items in the world are manufactured. It works by manufacturing and delivering products together in groups or batches. It is the manufacturing standard for production lines.

Raw materials and components undergo multiple steps as they are processed and assembled into a final product. The size and grouping of batches is decided by the manufacturer, and allows cycles to produce multiple iterations of an item simultaneously instead of one by one.

For example, in the pharmaceuticals industry, medication is produced in batches that undergo several processes depending on logistics and demand. Depending on the item being produced, the batch undergoes several steps such as processing, packaging, sterilizing, shipping, and inventory holding.

In this example of batch production, medication would be produced in batches of a hundred individual doses, and each batch would progressively go through processing, packaging, quality testing, etc. in one group. If a plant were not grouping items into batches, only one tablet would be produced at a time. 


A “batch” is a fixed number of units that are sent through processing. The batch size is determined by the manufacturer, but it is generally understood that batches are approximately the same size and fairly large, in order to ensure many units are produced on time according to demand.

Each batch goes through separate sub-assembly or processing stages until the final stage, where the batch is then checked for quality control.

The image below represents some of the biggest differences between batch production and its opposite, <a href="https://vksapp.com/dictionary/continuous-flow-manufacturing">continuous flow production</a>.


large_batchvscontinuous.jpg

medium_batchvscontinuous.jpg

small_batchvscontinuous.jpg

thumbnail_batchvscontinuous.jpg

batchvscontinuous.jpg

*[image courtesy of FDA US website]*

As you can see in the above image, there is no one right answer to the question of which process is best for lean manufacturing, batch or continuous flow. Some production cycles benefit from continuous flow organization, while others may thrive off of working in batches. 


## Benefits of Batch Production

Being the primary form of manufacturing across the globe, batch production has been well-tested and is the FDA industry standard. The biggest benefits of working in batches include:

- Potential for smaller, specialized manufacturers to sell components of bigger products
- Flexibility in response to supply chain disruptions
- Low cost
- Ability to produce variety of different products
- Familiarity and expertise within labor pool

Many manufacturers deal with mixed job orders, where they may be producing components of a larger product or an intermediary assembly or processing step before the final quality check.

In fact, some manufacturers specialize in certain sub-assemblies like packaging for distribution or creating and affixing a certain type of screw or veneer.

Batch production is by no means perfect, but it is definitely the most flexible overall for manufacturers who have access to certain sourced raw materials or specialty skills in niche areas.




### Why Batches? It Just Makes Sense!

To simplify this explanation, think about baking cookies. If you wanted to eat some delicious chocolate chip cookies, you’d break out a recipe and start combining ingredients.

It would be weird if, after all the mixing and preparatory work, you opened the oven and had… one cookie. 

Cookies are usually made in *batches*, anywhere from 12-24 individual cookies. They are all placed on the same tray and cooked in the same oven, and ideally, cool off on the counter at the same time.

It would be a waste of time to only bake one small cookie at a time when you could make a dozen. After all, who just wants ONE cookie?

## Risks of Batch Production

The risks of batch manufacturing are well-known, since it has been the primary form of large scale production for decades. Here are a few of the most prevalent risks:

- Degradation of materials (especially prevalent in pharmaceuticals)
- Delayed release for testing and quality control
- Late to respond to fluctuations in supply and demand
- Supply chain disruptions when transporting components
- Scaling up for demand requires big additional equipment buy-in
- Labor-intensive

The risks of batch production have less to do with safety and more to do with the increase of waste and defects in the production process. 

For example, when certain pharmaceutical drugs are produced in batches, semi-processed or raw materials can be placed in inventory or shipped elsewhere for further processing. This means that disruptions in the overall production process can lead to degradation of the materials’ quality and effectiveness.

This is also true when it comes to scaling up or down production according to demand. Because batches are prepared for processing one at a time, if a factory were to suddenly respond to increased demand, manufacturers would have to purchase additional equipment in order to double the output. It’s not as simple as pushing batches through production in greater frequency.

There is a higher amount of waste in batch production processes than in others like continuous flow manufacturing, for example. Because the thorough quality checks occur after the batch has been processed, it is possible that the entire batch can be discarded if there is a quality problem. 

Additionally, the human operators come into contact with the batch at several stages of the batch’s processing, meaning there is a greater possibility of human error or biological contamination.



### Why Not Batches? It's Wasteful!

Let’s revisit the above cookie example, where we agreed it was silly to bake one cookie at a time. This time, the circumstances are different.

Let’s say you were starting a small cookie business, and your hook is advertising fresh, right-out-of-the-oven chocolate chip cookies every day from 9-5 for hungry customers.

In this case, it’s not smart to make a few dozen cookies at 9am and sell them over the course of the day, because they won’t be fresh by the time the later crowd orders them. 

Additionally, what if you completed a massive batch, maybe four dozen, only to discover after baking that you had substituted baking soda for baking powder – an understandable but devastating mistake! Now the taste is ruined and you have to start all over again.

However, if you had prepped maybe half a dozen cookies every couple hours, you would be ensuring freshness as well as limiting potential waste in the case of a ruined batch. 

*But isn’t making 6 cookies at a time more frequently – rather than 60 cookies at once – just a form of batch production with smaller batches?*

Technically, yes, and that’s where you’ve spotted the end of the metaphor! Technically speaking, you would be minimizing batch size in this scenario. In manufacturing, however, it’s often impossible to “just make smaller batches” due to the mechanical equipment requiring maximum loading capacity in order to meet order demands. 

Batch production is the means by which most items in the world are manufactured. It works by manufacturing and delivering products together in groups or batches. It is the manufacturing standard for production lines.

## 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. 

## What is a Bill of Materials?

A Bill of Materials (BOM) is a list of the raw materials, sub-assemblies, sub-components, parts, and the required quantities to assemble, construct, manufacture, and repair a desired end product. 

Bills of materials are often associated with a corresponding production or work order, especially if using a work instruction platform. When the work order comes down the line, manufacturing operators have a list of the materials they need along with the instructions to manufacture the product. 

Due to their strong association with work/production orders, BOMs are a strong means of communication within a facility and between partnering companies regarding the requirements and usage of materials. 



## How to Structure Your BOMs

There are numerous ways to structure your BOMs. But before we get into the weeds of the different structures that companies and departments will use, there are a few simple guidelines that most BOMs should follow. 

- **Create a hierarchical structure**: A good rule of thumb is to structure your bills of materials in a hierarchical view. The finished product goes at the top, the base components are in the middle, and the base materials rest at the bottom. 
- **Give each item a clear name**: Workers should be able to quickly identify every part or material by a detailed and comprehensive name. 
- **Give each item in the list a numerical value**: Every item should have a unique part number. A serialized part number allows for better verification and tracking of the materials and helps to mitigate miscommunications. 
- **Qualify the quantity and units of measure**: BOMs need to be specific, especially if you are tracking inventory through an ERP. The number of materials types used along with the specific size of each component are invaluable metrics to keep track of. 


Did you know you can connect your Bill of Materials to your <a href="https://vksapp.com/dictionary/enterprise-resource-planning-erp">ERP</a>, <a href="https://vksapp.com/dictionary/material-requirements-planning-mrp">MRP</a> or <a href="https://vksapp.com/dictionary/mes">MES</a> through our <a href="https://vksapp.com/dictionary/application-programming-interface">API</a>? It all starts with creating visual instructions and comprehensive BOMs in VKS. 

## 2 Types of Bills of Materials: EBOM vs MBOM

There are 2 main types of BOMs that are extensively used within the industrial environment. These are the Engineering Bill of Materials (EBOM) and the Manufacturing Bill of Materials (MBOM). Each material list has key strengths that are beneficial to a specific type of user and department. 

### Engineering Bill of Materials (EBOM)

Engineering Bills of Materials (EBOM) are like a master list of materials and components. Generally, these lists are created using 3D drawings, such as CAD models, that specify the part numbers, quantities, measurements, and supplementary engineering notes on each component. 

EBOMs include product code, part name & number, part description, quantity, size, length, weight, and additional features.

Some engineering bills of materials will also list the known alternatives and substitutions that can be used to fabricate or assemble the product within specifications. This level of specificity is what sets this BOM on a level of its own. However, one could argue that it provides too much information for workers who build the product on the shop floor.

### Manufacturing Bif of Materials (MBOM)

Although very similar to an EBOM, Manufacturing Bills of Materials (MBOM) are less concerned about how the product is designed and more concerned about the parts that are needed to assemble the product. List items like alternatives and substitutions are not typically found in an MBOM. This shift in focus allows MBOMs to get straight to the point and be more useful on a manufacturing floor. 

MBOMs are comprised of pertinent information regarding the assembly and completion of the end product while also detailing how the parts relate to each other. 

Additionally, MBOMs often list the packaging materials that enable the product to be sent to the customer, which EBOMs do not typically have. 



Did you know that <a href="https://vksapp.com/case-studies/smith-induspac-precision-is-key">Smith Induspac</a>, a leader in industrial packaging, uses VKS work instruction software to build reliable and precise packaging materials for themselves and their customers?

## BOMs and Work Instruction Software

While BOMs give engineers and manufacturing operators the key parts and materials required to create a product, they lack in-depth instructions on how to build them. 

Imagine a cake recipe. The ingredient list is insurmountably important. Without it, your ingredient ratios will be off, affecting the taste and texture. But you also need a detailed process to mitigate adding ingredients at the wrong time or in the wrong order. 

While BOMs hold much more information than a typical cake ingredient list, they do not provide a complete picture or all the required information to build the end product. The process and the ingredient/materials list need to be mapped out together into a single operation.

<img src="https://strapi.vksapp.com/uploads/BOM_VKS_f3ab9af687.jpg" alt="BOM-VKS" className="center">

Detailed <a href="https://vksapp.com/products/pro">digital work instructions</a> have a BOM list embedded into every process and procedure. The BOM list is automatically retrieved from your <a href="https://vksapp.com/dictionary/enterprise-resource-planning-erp">ERP</a>, <a href="https://vksapp.com/dictionary/material-requirements-planning-mrp">MRP</a> or <a href="https://vksapp.com/dictionary/mes">MES</a> and pushed to the work instructions through our advanced <a href="https://vksapp.com/blog/api-capabilities">API</a>. Users can then review the always-up-to-date BOM list at any point in the procedure.

BOM integration with digital instructions enables companies to seamlessly review, track, and organize material usage and requirements for every product. At the same time, manufacturing operators and engineers receive a comprehensive procedural guide that leaves nothing to chance, giving every worker the right information at the right time. 


A Bill of Materials (BOM) is a list of the raw materials, sub-assemblies, sub-components, parts, and the required quantities to assemble, construct, manufacture, and repair a desired end product. 

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

large_cloudcomputing.jpeg

medium_cloudcomputing.jpeg

small_cloudcomputing.jpeg

thumbnail_cloudcomputing.jpeg

cloudcomputing.jpeg

## 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.


large_plugintocloud.jpeg

medium_plugintocloud.jpeg

small_plugintocloud.jpeg

thumbnail_plugintocloud.jpeg

plugintocloud.jpeg

## 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


large_gearscloud.jpeg

medium_gearscloud.jpeg

small_gearscloud.jpeg

thumbnail_gearscloud.jpeg

gearscloud.jpeg

## 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.


## What is Connected Factory Technology?

Connected factory technology enables manufacturers to share information quickly and accurately among their people, systems, equipment, and machines.

Have you heard the expression: “Knowledge is power”? 

Connected factory technologies bring knowledge and insight to the forefront of manufacturing operations, empowering people and their digital/physical tools to become smarter and self-sustainable. 

In many ways, the connected factory is the next phase of Smart Manufacturing practices. Intelligent systems connect to each other to form a centralized and standardized <a href="https://vksapp.com/dictionary/digital-thread">digital thread</a> of data, insight, and decision making prowess. 


## Why Is It Crucial to Use Connected Factory Technology?

With the advent of Industry 4.0, a number of sophisticated systems were created to aid workers and operations within the manufacturing environment. These systems were able to achieve higher levels of productivity but there was one problem. 

These systems couldn't consistently interact with one another, meaning that communication between processes and departments was still largely dependent on manual processes. When quality information needed to be shared with R&D, someone would have to retrieve the information and then manually send/deliver the information.

Now, connected factory technologies allow manufacturing systems and tools to automate and regulate themselves for an optimal workflow that is both efficient and self-sustaining.

<img src="https://strapi.vksapp.com/uploads/Connected_factory_production_line_bc5032710e.jpg" alt="connected factory technology" className="center">

## The 3 Manufacturing Goals of Connected Factory Technology

With the help of APIs and IoT devices, companies are steadily integrating connected factory technology into their operations. While this may sound well and good, most companies will be curious about the specific goals of connected worker technology. 

Here at VKS, we see connected factory technology as an opportunity to fulfill the 3 following manufacturing goals. 

### 1. Centralized Data Sharing

As we said before, “Knowledge is power”. The more knowledge we have, the better decisions we can make. 

What if we have the knowledge but don't have access to it? Then the decision-making process becomes much more difficult. 

Connected factory technology, which connects systems, machines, and people, makes knowledge and information more accessible at every point of the manufacturing process. As soon as users perform an action in one section of the process, the other manufacturing elements have access to the data. 

### 2. Automated and Self-Sustained Processes

With a free flow of information, connected factories sustain and correct themselves with little human intervention, making an automated multi-system framework. Every stage of assembly is monitored and subject to quality control. If something does not meet the established production parameters, the product line quickly warns employees and, if required, stops production.

For example, imagine you run an assembly line where workers and automated machines assemble magnetic components used within <a href="https://vksapp.com/blog/edhr-medical-device-manufacturing">medical devices</a>. Workers receive the necessary parts for assembly and follow their <a href="https://vksapp.com/products/lite">VKS Work Instructions</a> to fulfill their tasks. At the end of the line, a robot arm and several cameras inspect the assembled components for quality control and assurance. 

When a product passes the test, it records the serial number and places the component in a bin for shipping. At this point, the whole automated operation is aware of the successful part. Likewise, when there is a defective part, the robot arm places the piece in a labeled bin, records the product’s serial number, and automatically creates a new work order for rework within the work instructions.

Similarly, connected factory technology enables machines and equipment to regulate themselves and avoid bottlenecks or stalls within the production line. When there is a machine malfunction, the machine communicates with the MES to issue a maintenance work order and adjust the production flow to account for the problem. 

### 3. Enhance Worker Value

The purpose of connected factory technology is to empower the workers in the business and process. And with incredibly fast communication between systems and machines, this is more possible than ever before. 

Every person within the manufacturing environment is empowered to make better decisions and create more value for the customer and the company.

For supervisors and managers, connected factory technology enables them to gain a complete perspective of their business processes, machines, systems, tools, and people. As this knowledge is quickly available and highly accurate, the connected factory opens the doorway to smarter and more effective decision-making. 

For workers on the shop floor, enhanced communication and automated processes enable the connected factory to take over the simple yet time-consuming tasks of the manufacturing floor. Now, workers can offer distinctively human insight and focus on tasks that computers are unable to execute.

Engineers benefit from the technology through a complete 360-degree view of every process. This access to information empowers engineers to quickly address issues, perform <a href="https://vksapp.com/dictionary/root-cause-analysis">root cause analysis</a>, and find the right solutions for their production lines. 

## Connected Factory Technology: Work Instruction Software

One of the key contributors to connected factory technology is <a href="https://vksapp.com/work-instruction-software">VKS Work Instruction Software</a>. With its innate ability to connect and integrate with other systems like <a href="https://vksapp.com/dictionary/enterprise-resource-planning-erp">ERPs</a>, <a href="https://vksapp.com/dictionary/mes">MES</a>, and BI Software through its advanced API, VKS engages and empowers people to do more and create the utmost value with every action. 

<img src="https://strapi.vksapp.com/uploads/VKS_Connected_factory_technology_aec7e96527.png" alt="VKS and connected factory technology" className="center">

For example, automated processes involving machines are often far removed from processes involving people. But VKS, a tool that strives to provide the best of <a href="https://vksapp.com/dictionary/industry-5-0">Industry 5.0</a>, connects the two seemingly disparate operations, enabling manufacturers to gain incredible human insight while maintaining high levels of precision with every procedure and task. 

Assembly operators use a visual <a href="https://vksapp.com/dictionary/guidebooks-work-instructions">guidebook</a> that provides step-by-step instructions on the specifics of every procedure, enabling human actions to be highly standardized, accurate, and productive. As workers perform their duties, VKS gathers data that is then shared with other systems to optimize quality, track inventory, augment production, and more. 

The connected factory depends on technology that can easily integrate with other high-value manufacturing systems. VKS makes this happen while enhancing the actions of the people that matter most.


Do you want to see a connected factory In action? Discover how VKS and other connected factory technologies  have banded together to create a <a href="https://vksapp.com/blog/connected-factory-changes-everything">Connected Factory at IMTS 2022</a>.

Connected factory technology enables manufacturers to share information quickly and accurately among their people, systems, equipment, and machines.

## What Is The Connected Worker?

A Connected Worker enhances their manufacturing skills and capabilities through the direct implementation of digital technologies. More precisely, connected worker technology enables manufacturers to digitally connect and interact with their cyber-physical systems, allowing workers to gather and share critical information while performing their tasks more efficiently. 

As the manufacturing industry becomes more pressed for time and resources, efficiency and intelligent practices are a vital focus of any modern business. 

**The goal is to work smarter, not harder.**

Connected workers are one of the leading means of achieving this goal. With cyber-physical systems that increase an operator’s skills, insight, and collaboration, the connected workforce is better able to solve problems, act quickly, and generate valuable data for company growth.


## Why is The Connected Worker Important?

Due to the rise of <a href="https://vksapp.com/blog/connected-worker-platform-new-connected-economy">e-commerce and advancing technology</a>, the global market demands more complex and differentiated products. With manufacturing complexity steadily increasing, profit margins become tighter and tighter. 

However, by enhancing the capabilities of their workforce through connected worker technology, manufacturers can uncomplicate their productions and maximize their savings. 

One of the main ways manufacturers are implementing connected worker technology is by collecting their organization's <a href="https://vksapp.com/dictionary/tribal-knowledge">tribal knowledge</a> and digitally sharing it with the complete workforce.

Connected workers are confident in their abilities regardless of their experience level because they have a connected worker platform that digitally presents the right working methods in a step-by-step guidebook. 

### How Does Connected Worker Technology Work? 

Connected worker technology, such as <a href="https://vksapp.com/work-instruction-software">work instruction software</a>, achieves high levels of efficiency through two main functions:

1. Automated actions
2. Cyber-physical interactions

First, the connected worker platform connects to the worker through <a href="https://vksapp.com/blog/autonomous-smart-work-instructions">automatred processes</a> like collecting data, sending information, entering part numbers, etc. While employees follow their work instructions, the connected worker platform reacts to the events of the production line and the actions of the operator.

<img src="https://strapi.vksapp.com/uploads/connected_workers_2c91f47b76.jpg" alt="connected workers" className="center">

In the case of data collection, the application can seamlessly communicate with your <a href="https://vksapp.com/dictionary/enterprise-resource-planning-erp">ERP</a> and <a href="https://vksapp.com/dictionary/bi-software">BI software</a> via an <a href="https://vksapp.com/dictionary/application-programming-interface">API</a>. The operator does not need to manually relay data or information. The connected worker platform is taking care of it. 

Secondly, our work instruction software connects with the worker through intelligent interactive methods. These include: 

- <a href="https://vksapp.com/blog/smart-tools-smart-enough">Smart Tools</a>: Connected smart tools such as smart torque wrenches enable connected workers to capture key data, gain advanced knowledge, and error-proof processes with every work-related interaction. Through the capabilities of <a href="https://vksapp.com/products/connect">ToolConnect IoT</a>, workers are connected to their software without ever having to touch their computer screen. 

- <a href="https://vksapp.com/dictionary/smart-forms">Smart Forms</a>: These forms provide connected workers with a quick and easy way to share additional insight and knowledge with the team and operation. The information captured in smart forms is collected and sent to the appropriate groups.
 
- **Dynamic Guidance**: Based on operator inputs, VKS work instructions, and our <a href="https://vksapp.com/dictionary/rule-engine">rule engine</a> will bring the operator to the next appropriate step in their guidebook or open the required smart forms. This interactivity enables <a href="https://vksapp.com/dictionary/guidebooks-work-instructions">guidebooks</a> to be responsive to the situation at hand. 

- **Visual Interaction**: Since people assimilate visual knowledge first, visually interacting with your software is a powerful method to connect with the worker. Instead of requiring the worker to scan, read, and sift through instructions, they can see the work in front of them and follow the actions on the screen. 

These methods streamline interaction and turn the connected worker and their software into a well-founded team. Both the person and their connected worker technology have specific duties and responsibilities that aid in achieving a strong operation. 


Discover more about <a href="https://vksapp.com/blog/interactive-work-instructions">interactive work instructions</a> and how you can seamlessly connect your workers through intelligent and collaborative software. 

## Who Can be a Connected Worker? 

Connected workers can be anyone within an organization as long as they are enhancing their capabilities through the use of digital technologies. 

For instance, let’s use work instruction software as an example. The platform connects people to their work and enhances the following positions in the manufacturing environment. 

- **Workers** connect to their work through their digital work instructions. This connection to step-by-step guidebooks enables workers to perform a wide array of jobs and responsibilities that they could not normally remember on their own.

- **Supervisors** and team leads keep track of training and workforce skills with individual profiles of each worker. This level of tracking optimizes <a href="https://vksapp.com/blog/enhance-workforce-training">strategic workforce planning</a> easily. 

- **Managers** take employee-generated data and strategically plan production schedules, optimize efficiency, monitor employee output, and reduce expenditures. They also gain the ability to receive feedback in real time from their connected employees.

- **Maintenance workers** use work instruction software to gain standardized maintenance practices that allow them to troubleshoot issues they’ve potentially never seen before. With the help of the <a href="https://vksapp.com/blog/what-is-a-rule-engine">VKS rule engine</a>, maintenance worker interactions will lead to the next appropriate step in the guidebook. 

- **Engineers** use VKS to ensure that the process is done correctly every time. By creating work institutions that are <a href="https://vksapp.com/blog/how-to-write-good-work-instructions">geared for the operator</a>, engineers can rest assured that their processes are followed correctly and that the data collected is standardized.

<img src="https://strapi.vksapp.com/uploads/connected_worker_collaboration_e918b1e6e4.jpg" alt="connected worker collaboration" className="center">

## The 3 Major Benefits of The Connected Worker

The connected worker platform is both physical and digital. Physically connecting to your work is nothing short of amazing and efficient. The industry has seen major leaps forward regarding smart tools and <a href="https://vksapp.com/blog/industrial-wearables-changing-manufacturing">industrial wearables</a>. But the limitless power of connected worker technology is its ability to collect, store, transfer, and relay knowledge digitally.

With this incredible capability, there are 3 key benefits that the connected worker brings to the table

### 1. Continuously Upskill Your Workforce

With access to vast stores of knowledge and a constantly improving standardized process infrastructure, a connected workforce’s skills are always trending upwards. As soon as your company improves a process or adopts a new procedure, your connected worker uses it immediately. This accelerated adaptation to better techniques and skills leads to an operation poised for growth. 

The greater the skills of your workers, the greater the output of your operation. 


Enhance the capabilities of your workforce with digital work instructions that guide workers in an easy step-by-step format. Use pictures, videos, and annotations to achieve process compliance for every one of your processes.

### 2. Reliable Data that is Available in Real Time

As every one of your processes becomes digitally standardized, your data becomes more reliable and trustworthy. For example, if all of your workers follow the same methods, tracking quality defects and production times becomes a whole lot simpler. 

Plus, connected worker platforms gather data from every action taken by a worker on the shop floor, meaning that you gain a real-time picture of your operation, processes, and procedures. 

For instance, if you are assembling the base components for a larger product, it is beneficial to track the individual times and progress of each sub-production line. If some production lines are either under or over-efficient, you can adjust factors to ensure that the products are ready <a href="https://vksapp.com/dictionary/just-in-time">just in time (JIT)</a>. 

This level of insight into worker processes is impossible without connected worker platforms like work instruction software.

### 3. Increased Teamwork Between People and Departments

The connected worker opens up the doorways to enhanced collaboration between departments and workers. If all workers are connected to a centralized digital hub, then the data they generate can be used by other departments and production silos. 

This centralized hub provides a transparent flow of information that users can share with the organization and the supply chain. 

Connected workers can also communicate directly with managers and other team members by interacting with their software. Whether there are issues, safety alerts, or production changes, connected workers can collaborate with the whole team intelligently and efficiently. 


Use the <a href="https://vksapp.com/blog/digital-supply-chain-ecosystem">VKS Digital Ecosystem</a> to accurately track production information and share valuable process knowledge across your supply chain. With this connected worker technology, suppliers, distributors, material handlers, warehouses, and more have the information and knowledge they need to get you the materials and components you need.

A Connected Worker enhances their manufacturing skills and capabilities through the direct implementation of digital technologies. More precisely, connected worker technology enables manufacturers to digitally connect and interact with their cyber-physical systems, allowing workers to gather and share critical information while performing their tasks more efficiently. 

Continuous Flow is a type of manufacturing process that builds items beginning to end in one production line without scheduled interruptions. It is a type of materials processing where the material undergoes mechanical, thermal, or chemical treatment continuously.

This method has been used in chemical and materials manufacturing for decades and has recently been introduced to the pharmaceutical industry. 



Before we get into the nitty gritty, here’s a helpful chart comparing continuous flow and batch production that highlights the biggest differences between the two:

*[image courtesy of FDA US website]*

## Challenges of Continuous Flow

The biggest challenge of continuous flow manufacturing is that all necessary steps of production must be in the same location, working seamlessly and uninterrupted. This kind of workflow coordination requires a very strong culture of organization and clear levels of command between team leaders. 

Here are more challenges of adopting continuous flow manufacturing:

- Operators need extensive training
- Lack of coordinated industry regulations
- Not modular and cannot be easily repurposed
- High cost of buy-in
- Harder for customization within production
- Higher difficulty coordinating scheduled maintenance
- Production occurs 24/7, requiring fewer workers overall but more overlapping shifts

Because the automated systems required for continuous flow production are so specifically integrated with each other, it is difficult, if not impossible to repurpose equipment for other types of production, such as <a href="https://vksapp.com/dictionary/batch-production">batch production</a>.

Continuous flow systems are indeed *systems*, not individual machines stacked end-to-end. This means that as well as being largely difficult to repurpose, continuous production systems also cannot easily be scaled to different production cycles of the same item, such as batch processing. 

In other words, manufacturers who rely upon continuous flow do not have the option of making “extra” and keeping it in inventory. They also cannot respond to lack of demand by making “just a few” products at a time. 

There is a bigger buy-in for this type of manufacturing because it is not as modular as batch production. The technology for a fully integrated continuous flow manufacturing system is still fairly new. 

It is true that there is a lack of coordinated regulation for continuous flow, but the reason for that is that it is not widely used outside of materials and chemicals processing. Now that continuous flow systems can be oriented for pharmaceuticals, industry standards are sure to catch up.

Moreover, the labor challenges with continuous flow manufacturing are a major point of concern because of the current labor shortage and skills gaps within the manufacturing industry.

Operating continuous flow systems may save on labor costs in the long run, but in the short run, manufacturers should expect a high cost of investing in training and education for their shop floor workers.

## Benefits of Continuous Flow

There are numerous benefits of adopting a continuous flow style of production:

- More ‘Agile’ than other production processes
- Can produce smaller quantities of product with less waste 
- Much shorter production times
- High level of compatibility with IIoT
- Reduces the possibility of human error
- Safer for employees when handling dangerous or unstable chemicals
- Saves energy costs by not having to power up and down machines constantly
- Streamlined process with no unnecessary steps costing time and labor
- Uncovers quality issues that may be hidden within inventory
- Production occurs 24/7 with little to no downtime

With all of the integrations built into a continuous flow model, such as sensors for measurement and preventative maintenance, the Smart Factory is an excellent candidate for adopting such a system of production.

Because continuous flow models need to move in harmony with great precision, most of the human labor required in traditional production processes is eliminated.

While this reliance upon automation saves money on labor costs, it is balanced out by the extensive training required to operate the machinery.

Overall, Smart sensors and other technologies can minimize the waste produced in a continuous flow production line: alarms will sound if there is an error, allowing workers to immediately fix the problem, rather than waiting for a quality check at the end of the production process like in batch processing. In the latter scenario, if a defect is found, then the whole batch may need to be discarded. 

The same issue of waste is prevalent in the pharmaceutical industry, where drugs produced in batches and then stored for shipping or later processing can be contaminated or lose potency over time.



vaccines produced using continuous flow manufacturing

large_contflow.jpeg

medium_contflow.jpeg

small_contflow.jpeg

thumbnail_contflow.jpeg

contflow.jpeg

### The Future of Continuous Flow

Continuous flow manufacturing has historically been used for chemical processing plants. This is ideal because in this type of manufacturing, raw materials undergo massively fluctuating temperatures and pressures in order to undergo chemical reactions. 

Here are some of the industries that make heavy use of this type of production:
- Pulp and paper 
- Power stations
- Fertilizer 
- Oil refineries
- Synthetic fibers
- Natural gas
- Wastewater refineries

These examples help show why continuous flow is the standard of manufacturing: rarely are waste or oil refineries producing items “to order”. Since these materials and processing procedures are continuously in demand for basic living conditions and almost every area of commerce, it makes sense to keep these plants open 24/7.

Additionally, because these plants refine materials under massively intense conditions (like the heat levels needed to melt steel), it would be a huge waste of resources – energy, time, money, and labor – to start and shutdown the mechanics every day on a 9-5 schedule. It makes much more sense, as well as being safer for workers, to keep these machines on 24/7.

Nowadays, the pharmaceutical industry is taking pointers from these classic materials manufacturers. Even though medication in tablet or capsule form seems like a “smaller” type of production, many pharmaceuticals undergo the same intensity of chemical reactions.

In today’s modern world, especially as we continue to move through the Fourth Industrial Revolution, the constant supply of basic medication – like Ibuprofen – is just as critical as the supply of metallurgical resources – like iron – for example.


Continuous Flow is a type of manufacturing process that builds items beginning to end in one production line without scheduled interruptions. It is a type of materials processing where the material undergoes mechanical, thermal, or chemical treatment continuously.


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.


large_skillup.jpeg

medium_skillup.jpeg

small_skillup.jpeg

thumbnail_skillup.jpeg

skillup.jpeg

### 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

large_xtrainworkinstructions.jpeg

medium_xtrainworkinstructions.jpeg

small_xtrainworkinstructions.jpeg

thumbnail_xtrainworkinstructions.jpeg

xtrainworkinstructions.jpeg

### 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.


large_blue background network.jpeg

medium_blue background network.jpeg

small_blue background network.jpeg

thumbnail_blue background network.jpeg

blue background network.jpeg

## 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. 



large_cross-skill shift.jpeg

medium_cross-skill shift.jpeg

small_cross-skill shift.jpeg

thumbnail_cross-skill shift.jpeg

cross-skill shift.jpeg

### 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.


large_xtrainingmatrix.PNG

medium_xtrainingmatrix.PNG

small_xtrainingmatrix.PNG

thumbnail_xtrainingmatrix.PNG

xtrainingmatrix.PNG

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.

large_employeesclapping.jpeg

medium_employeesclapping.jpeg

employeesclapping.jpeg

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

Work Instruction Software

By Use Case

By Industry

VKS Integrations

Overview

Lite

Pro

Enterprise

Add-Ons

Partnership

VKS Dictionary

Manufacturing Term of the Week

5M+E

Subscribe to Our Newsletter

Case Studies

Solutions

ROI Calculator

Why VKS

Application page

Industries

Products

Insights

Company

Blog

Newsletter Sign up