Procurement 101: Shop Floor Control – How it works and how to leverage it

In this article, we’ll dive deep into what shop floor control is, the challenges manufacturers face in implementing it, the solutions to overcome those challenges, and the exciting trends and future outlook for this critical technology. Get ready to learn how shop floor control is revolutionizing the factory floor and driving the future of manufacturing.

What is shop floor control?

Shop floor control is a critical manufacturing process that tracks and orchestrates the progression of work through the production facility. It encompasses the set of tools, systems, and procedures that manage the flow of materials and products from raw materials to finished goods. The goal of shop floor control is to ensure smooth and efficient operations, optimize resource utilization, and meet production schedules and customer demand.

Think of shop floor control as the conductor of a symphony orchestra. Just as the conductor ensures each musician plays their part at the right time to create a harmonious performance, shop floor control systems coordinate the various elements of production – people, machines, materials, and processes – to manufacture products on time and to spec.  

Benefits and key aspects

Without effective shop floor control, manufacturing operations would quickly devolve into chaos. Work-in-process inventory would pile up, machines would sit idle waiting for parts, defects and quality issues would proliferate, and on-time deliveries would plummet. In short, the factory would grind to a halt.

Key aspects of shop floor control include:

• Production scheduling and sequencing
• Work order management and tracking
• Labor and machine allocation
• Quality control and inspection
• Inventory management
• Data collection and reporting

The shop floor control process generates critical outputs like work orders, production schedules, inventory transactions, labor records, and performance reports. This real-time data provides visibility into the state of production at any given moment, allowing managers to make informed decisions.

Of course, shop floor control is just one piece of the manufacturing puzzle. It must integrate with related systems like ERP, MES, and supply chain management to provide true end-to-end control and optimization. But as the direct link to the actual making of the product, shop floor control is truly where “the rubber meets the road” in manufacturing.

Recent trends and future outlook for shop floor control

In recent years, shop floor control has been transformed by the rise of Industry 4.0 technologies. The IoT, big data analytics, and AI are enabling real-time visibility, predictive maintenance, and autonomous decision-making on the factory floor.

Another trend is the move towards cloud-based and mobile solutions. Cloud computing allows for scalable, flexible shop floor control systems that can be accessed from anywhere. Mobile devices enable operators and managers to monitor and control production on-the-go. For instance, Plex Systems offers a cloud-based MES with mobile capabilities.

Looking ahead, the future of shop floor control lies in the convergence of these technologies. We can expect to see more intelligent, self-optimizing production systems that leverage vast amounts of data from across the factory and beyond. The integration of shop floor data with enterprise systems will enable end-to-end visibility and optimization.

Solutions to shop floor control challenges

Here are some specific tools and software that can support digitizing shop floor control.

Manufacturing Execution Systems (MES)

MES software provides real-time visibility and control over the entire production process. It tracks and manages everything from raw materials to finished products, enabling manufacturers to optimize production schedules, monitor quality, and respond quickly to issues. Examples include:

• Plex Manufacturing Cloud
• Rockwell FactoryTalk ProductionCentre
• Siemens Opcenter Execution
• Tulip

Industrial Internet of Things (IIoT) Platforms

IIoT platforms connect machines, sensors, and devices on the factory floor, allowing for real-time data collection and analysis. This data can be used to monitor equipment performance, predict maintenance needs, and optimize processes. Examples include:

• PTC ThingWorx
• GE Predix
• Siemens MindSphere

Advanced Planning and Scheduling (APS)

APS software uses advanced algorithms to optimize production schedules based on real-time data. It can help manufacturers balance demand with capacity, minimize changeover times, and improve on-time delivery. Examples include:

• Dassault Systèmes DELMIA Quintiq
• Siemens Opcenter APS
• SAP Advanced Planning and Optimization

Quality Management Systems (QMS)

QMS software helps manufacturers ensure consistent quality by monitoring and controlling quality processes. It can track quality metrics, manage quality documentation, and facilitate continuous improvement. Examples include:

• ETQ Reliance
• Sparta Systems TrackWise
• MasterControl Quality Excellence

Digital Work Instructions and Electronic Batch Records

Digital work instructions guide operators through production processes, ensuring consistency and reducing errors. Electronic batch records capture all data related to a production run, providing a complete digital history for traceability and compliance. Examples include:

• Poka
• Dozuki
• MasterControl Manufacturing Excellence

Industrial Analytics and AI Platforms

These platforms apply advanced analytics and artificial intelligence to shop floor data, enabling manufacturers to uncover insights, predict issues, and optimize processes. Examples include:

• Microsoft Azure Industrial IoT
• IBM Watson IoT
• Google Cloud Manufacturing AI

Integration Platforms

Integration platforms help connect different shop floor systems and data sources, enabling a holistic view of operations. They provide APIs, connectors, and tools to simplify integration and data exchange. Examples include:

• Software AG webMethods
• Mulesoft Anypoint Platform
• Boomi AtomSphere

Conclusion

As we’ve seen, shop floor control is not just a tool, but a strategic imperative for manufacturers in the Industry 4.0 era. By leveraging the power of advanced technologies like IoT, AI, and cloud computing, manufacturers can gain unprecedented visibility, control, and optimization over their production processes. But the journey to effective shop floor control is not without its challenges. It requires careful planning, change management, and the right technology partners.

The manufacturers that get it right will be the ones that thrive in the face of increasing competition, customer demands, and market dynamics. They will be the ones that can consistently deliver high-quality products, on-time and on-budget. They will be the ones that can continuously learn, adapt, and innovate on the factory floor. In short, they will be the manufacturers of the future.

So if you’re a manufacturer looking to stay competitive in the Industry 4.0 era, the time to act on shop floor control is now. The future of manufacturing is here – are you ready to seize it?

‍