The complex nature of custom manufacturing involves many processes where engineering issues can arise. In a recent Fast Radius survey, 250 bespoke manufacturers were asked to name the top technical challenges that hinder their business. Topping the list were lack of communication, quality issues, and rushed development cycles. Another pain point engineers face on a daily basis are inefficient processes that waste time and undermine data accuracy.
The good news is that there is a way to alleviate
these difficulties.
An enterprise resource planning (ERP) system provides
a centralized database that improves communication and data management and
helps optimize processes, all of which makes the work of engineers easier. By
adopting an ERP, manufacturers increase the efficiency, quality and overall
competitiveness of their operations.
1, Lack of communication
The main problem cited by engineers surveyed by Fast
Radius is the lack of communication. Too often, in custom manufacturing
factories and workshops, different departments work in isolation, which hinders
collaboration and communication between teams. However, poor communication
between departments and teams can not only slow down the production process,
but also be a source of errors and inefficiency.
ERP systems break down communication silos by
integrating information and processes across an entire company. They provide
custom makers with the tools their teams need to collaborate on focused tasks,
assignments, or projects. For example, engineers can use an ERP to track
project progress, share design briefs, and communicate with various key
departments.
ERPs are also a unique "truth" filter for a
company's data. The fact that everyone can access the same exact information in
real time eliminates the risk of misunderstandings and errors caused by
outdated or inaccurate information.
But of course, the lack of communication does not only
exist within the same company, but also between custom manufacturers and
third-party partners. ERPs alleviate these problems by allowing manufacturers
to communicate more easily with their partners, suppliers and customers. By
bringing all customer data together in one system, they make it easier to
interact and communicate with them. Instead of a slow back and forth between
customers and engineering and design departments, ERPs provide a streamlined
communication process. What's more, these systems can support a portal that
efficiently manages all communications with suppliers, making it easy to interact
with suppliers and ensuring the delivery of quality products and components on
time.
2, Inefficient processes
Too many bespoke manufacturers still rely on outdated
processes ‒ manual, paper or Excel ‒, "time wasters" that cause
errors and are difficult to manage.
ERPs help custom manufacturing factories and shops
standardize their business processes across an entire enterprise. Everyone
follows uniform instructions, which reduces the risk of confusion and
misunderstandings and promotes effective collaboration between teams. In
addition to standardizing business processes, ERPs automate many of them,
reducing the risk of errors and increasing efficiency.
In a factory or shop, one of the most inefficient
processes ‒ the one that wastes the most time for engineers ‒ is the manual
transfer of BOM from a computer-aided design (CAD) system to a ERP. Up to 20%
of engineers' working time is taken up by this tedious process ‒ time that
should be spent on more important tasks.
This is why an ERP system equipped with CAD2BOM can be
of great use to you. CAD2BOM (Computer-Aided Design to Bill of Materials)
allows you to set up a process that automatically converts your 3D CAD models
into a Bill of Materials and accurately lists all the components and data
needed to manufacture a product , including quantities, component numbers and
the name and role of suppliers involved.
CAD2BOM is essential for custom fabricators, as it
ensures that the components used in the fabrication are accurately designated
and are sufficientlyrecent. It ensures a direct link between product design and
its manufacturing process. An ERP equipped with CAD2BOM reduces the risk of
errors related to the use of a bad component or another that is no longer
available. Designed to ensure tight control of the manufacturing process,
CAD2BOM allows teams to validate each component and track its
"status".
In addition to increasing accuracy and efficiency,
CAD2BOM ensures close collaboration between engineering and manufacturing
teams, with everyone having access to the same accurate and up-to-date
information.
3, Rushed Development Cycles
Another frequently cited weakness in the Fast Radius
survey is the rush of the development cycle. Indeed, 58% of respondents indicate
that product development cycles have become too fast, which increases the
pressure on engineers.
One way for bespoke manufacturers to alleviate this
pressure is to implement concurrent engineering in their factories and
workshops.
Concurrent engineering is an approach to product
development that requires the simultaneous and synchronized work of teams from
various departments in the design, development and validation of a product.
Concurrent engineering reduces the time and cost to bring a product to market
by eliminating bottlenecks and streamlining the development process.
ERPs that support concurrent engineering allow custom
manufacturers to begin manufacturing (the first phase of a project) while they
are already working on subsequent stages.
By allowing multiple aspects of a product to be worked
on at the same time, concurrent engineering eases the pressure on engineers and
reduces the time it takes to bring a product to market. What's more, it enables
manufacturers to innovate more by bringing together interdisciplinary teams ‒
and their ideas ‒ in the development process.
Finally, factories and workshops that use concurrent
engineering can reduce the rate of rework and delays, which further reduces
costs, as potential problems are identified and resolved early in the
development process.
4, Inaccurate Data
Data inaccuracy is another pain point for engineers,
as inconsistent or inaccurate data can cause errors and slowdowns in design and
manufacturing processes. Without a centralized source of up-to-date
information, engineers make decisions based on inaccurate or outdated data,
leading to rework, rework, delays, or worse, the manufacturing of products or
faulty components.
To work well, engineers must have access to real-time
information (in English) on the progress of projects, the availability of
resources and the management of materials and materials. To this end, ERP
systems provide them with a centralized data warehouse, giving them the
overview they need to make informed decisions. With this single source of
"truth" for a company's data, everyone, including the engineering
department, can access the same information in real time, reducing the risk of
misunderstandings and errors caused by old or incorrect information.
Finally, ERPs with features and functionality tailored
to engineering activities, such as CAD2BOM or concurrent engineering, help
ensure that everyone on a plant or manufacturing floor is on the same
wavelength. For example, CAD2BOM ensures that every BOM is accurate and up-to-date,
improving collaboration between design and manufacturing teams, while reducing
the risk of manufacturing errors.
With their centralized platform of data available in
real time, ERP systems help custom manufacturers streamline their operations,
reduce the risk of errors and improve their overall performance.
5, Quality issues
Quality issues are another area of concern for
engineers who are dedicated to custom manufacturing. Many Fast Radius survey
respondents listed poor component quality as one of their most pressing
challenges.
Ensuring consistent quality in the manufacturing
process can be a challenge, as often defects appear in the absence of proper
quality control measures.
ERP systems provide a centralized database that can be
used to track and control the quality of raw materials, components, and
finished products. Manufacturers can thus detect and correct quality problems. early
in the process, reducing the risk of defects and increasing customer
satisfaction. An ERP with a good quality management system (QMS) helps custom
manufacturers increase quality and reduce non-conformance costs. It’s about
having a proven quality control system in place from the start. For example,
manufacturers can use their QMS to verify/inspect the quality of components
from their suppliers as soon as they receive them.
ERPs that support concurrent engineering can also help
custom manufacturers improve the quality of their products by bringing together
specialists from multiple disciplines in the development process. Concurrent
engineering ensures that all aspects of a product are considered and validated,
which more often than not enhances the quality of the final product.
Another advantage of ERP systems is that they provide
real-time data on production processes, allowing manufacturers to recognize and
correct quality issues in real time. In short, ERPs make it possible to store
and manage data and information that are used in particular to identify
opportunities for continuous improvement in the quality of products and
processes. Manufacturers can thus constantly raise the quality of everything
that comes out of their production line, which increases their competitiveness
and the satisfaction of their customers.
Make sure your ERP is built for engineers
Engineering issues can harm the operations of custom
fabrication factories and shops by reducing their efficiency and output, which
ultimately reduces their competitiveness. A good ERP ‒ a system specifically
designed for manufacturing activities ‒ streamlines and automates design and
manufacturing processes and improves communication and collaboration. By
equipping themselves with a quality ERP, custom manufacturers can become more
efficient, more productive, and more agile, as such a system mitigates
engineering issues that slow down projects and extend delivery times.
For more reasons why engineers need an ERP, check out
our Back to Basics – ERP for Engineers blog.