Prevent human error with production management software

Author:

Mohsen Shamsi

Category:

Articles

Study time: 14 minutes

Human errors in the production line

They can occur for various reasons and have various effects on production efficiency and quality. These errors usually occur due to the following factors:

۱٫ Inadequate training:

Employees may not be fully familiar with processes and machinery.

۲٫ Fatigue and stress:

Long working hours or stressful environments can reduce the accuracy and concentration of employees.

۳٫ Poor communication:

Failure to communicate important information between team members can lead to misunderstandings and operational errors.

۴٫ Lack of standardization of processes:

Lack of standard work procedures can cause changes and fluctuations in production quality.

۵٫ Environmental factors:

Unsuitable working environment conditions such as low light, high temperature and humidity or high noise can reduce the concentration of employees.

Types of human errors in the production line:

۱٫ Final errors:

including improper performance of assigned duties such as misalignment of machinery or use of inappropriate materials.

۲٫ Errors of negligence:

Including forgetting to perform certain tasks such as not checking the quality of products.

۳٫ Decision errors:

including making incorrect decisions when faced with unexpected problems or choosing inappropriate methods to solve problems.

۴٫ Communication errors:

It includes errors in the transmission of information or instructions between employees.

Ways to reduce human errors:

In this part, we will learn about the solutions to reduce human error in the production line.

Training and Retraining:

Conducting regular training courses: ensuring that employees are constantly familiar with new procedures and technologies.
Practical trainings and workshops: using practical trainings to increase the skills of employees.

Standardization and Documentation:

Creating standard work procedures: developing and implementing specific and repeatable procedures for all production stages.
Accurate documentation of processes: recording and maintaining the details of work steps in order to avoid forgetting or misunderstanding.

Improving Working Conditions:

Creating a suitable work environment: ensuring there is enough light, proper ventilation and reducing noise.
Stress and fatigue management: determining suitable working hours and creating rest programs for employees.

Utilizing Assistive Technologies:

Automation and Robotics: Using automated systems to perform repetitive tasks and reduce dependence on human labor.
Monitoring and control systems: using monitoring systems to identify and fix errors immediately.

Improving Internal Communication:

Facilitating communication between employees: creating effective and fast communication channels between all levels of the organization.
Regular feedback exchange: Encourage giving and receiving feedback in order to identify and resolve problems in a timely manner.

۱٫ Inadequate training:

Employees may not be fully familiar with processes and machinery.

Implementation methods to reduce human errors:

Error Analysis and Assessment:

Identifying error sources: using error analysis methods such as root cause analysis to identify the main causes of errors.
Risk assessment: assessment of risks associated with each stage of production and implementation of preventive measures.

Promoting a Safety Culture:

Promoting a safety culture: encouraging employees to follow safety principles and report errors without fear of punishment.
Creation of safety teams: formation of safety teams to monitor the implementation of safety standards and continuous improvement.

Decision Support Systems:

Use of advanced software: use of production and decision-making management software to help employees perform their duties.
Warning systems: installation of warning systems for quick notification in case of errors.

Fixing human errors using production line management software:

Using production line management software can significantly help in reducing human errors and improving production efficiency and quality. These softwares have many features and capabilities that can be effective in managing, monitoring, and optimizing production processes. Below are some of these features and benefits.

Features of the production line management software:

Inventory Management:

Accurate inventory control: accurate and real-time tracking of raw materials, semi-finished products, and finished products.
Demand forecasting: Use of forecasting algorithms to plan material supply and avoid shortages or unnecessary stockpiles.

Production Scheduling and Planning:

Production planning: determining the exact schedule for each stage of production in order to optimize the use of resources.
Resource Allocation: Managing the allocation of machinery, manpower and materials to increase productivity.

Quality Control:

Quality monitoring: recording and checking quality data at every stage of production and identifying defects in real time.
Standardization: Ensuring compliance with quality standards using standard checklists and protocols.

Production Monitoring and Control:

Monitoring dashboards: display the real-time status of production using graphic dashboards.
Alert systems: sending immediate alerts in case of problems or deviations from the program.

Analytics and Reporting:

Data Analysis: Analyze production data to identify patterns and areas for improvement.
Comprehensive reports: Generating comprehensive reports for managers to make better decisions.

These factors are just a few examples of elements that are used in production line management. The purpose of this approach is to sustainably improve the performance of the production line and create a work environment that increases productivity, reduces waste, and improves the quality of products.

Advantages of using production line management software:

۱٫ Reducing human errors:

Automation of processes: reducing the need for manual interventions and thus reducing the possibility of errors.
Guidance and support: providing detailed instructions and guidance to employees at every stage.

۲٫ Increasing productivity and efficiency:

Optimizing the use of resources: detailed planning and optimal allocation of resources to increase productivity.
Reduce downtime: Quickly identify problems and fix them to reduce unexpected downtime.

۳٫ Improving the quality of products:

Strict quality control: continuous monitoring of production quality and taking corrective measures in time.
Standardization of processes: creation and implementation of quality standards for all production steps.

۴٫ Better decision making:

Data-driven: providing accurate and analyzable data for strategic decision-making.
Up-to-date reporting: Providing up-to-date and detailed reports for performance evaluation and future planning.

Examples of production line management software:

SAP Manufacturing Execution

A comprehensive system for managing and monitoring production processes that has extensive possibilities for automation and quality control.

Oracle Manufacturing Cloud

A cloud solution for production management that offers advanced capabilities for production planning and control.

Siemens Opcenter

A comprehensive software for managing production operations with a focus on improving productivity and quality.

Plex Manufacturing Cloud

A cloud system that provides multiple possibilities for production management, quality control and inventory tracking.

Implementation of production line management software:

Needs analysis: identifying the needs and challenges in the production line to choose the right software.
Software selection: evaluation and selection of software according to capabilities, costs and compatibility with existing systems.
Training and preparation of employees: Training employees to use the software and prepare for changes.
Implementation and testing: installing and running the software and performing initial tests to ensure proper functionality.
Monitoring and continuous improvement: monitoring the performance of the software and updating and continuously improving it based on feedback and new needs.

Advantages of using production line software:

Using production line management software has many advantages that can significantly help reduce human errors and improve production efficiency and quality. In the following, we review the main advantages of using these software to prevent human errors in the production line.

۱٫ Automation of processes

Reduction of manual interventions: By automating processes, the need for manual interventions that can lead to human errors is reduced. Devices and systems can automate repetitive tasks.
Increasing accuracy and speed: Automation increases the accuracy and speed of performing tasks, because machines and systems have higher accuracy and speed than humans.

۲٫ Advanced quality control

Continuous quality monitoring: Production line management software allows real-time monitoring of product quality and can quickly identify and report quality problems.

Standardization of processes: These softwares help to establish and maintain quality standards and ensure that all products are manufactured according to established standards.

۳٫ Reducing decision making errors

Decision support: Software can provide comprehensive and accurate data that helps managers and employees make better decisions.
Warning systems: These systems can send immediate alerts in case of problems or deviations from the production schedule, which helps prevent wrong decisions.

۴٫ Inventory and materials management

Accurate inventory tracking: Production line management software can accurately track the inventory of raw materials and products, which prevents mistakes related to shortages or overstocks.
Optimizing the use of materials: These softwares can optimize the use of materials and prevent wastage of materials.

۵٫ Improving internal communication

Integrated systems: Production line management software often includes integrated systems that facilitate communication between different teams and departments.
Accurate information transfer: These softwares ensure that information is accurately and completely transferred between employees, which prevents misunderstandings and communication errors.

۶٫ Training and support

Employee training: Many production line management software includes training tools and user guides that can help employees familiarize themselves with new processes and systems.
Technical support: These software often provide technical support and advice to solve problems and continuously improve processes.

۷٫ Analysis and reporting

Data-driven: These software collect and analyze production data in real-time, which helps identify patterns and weaknesses.
Detailed reports: generate detailed and comprehensive reports for managers to evaluate performance and identify areas for improvement.

Practical examples:

Use of sensors and IoT:

Installing sensors on machines and using the Internet of Things (IoT) to collect data and monitor the performance of devices in real time.

ERP systems:

Integrating enterprise resource planning (ERP) systems with the production line to improve planning and coordination between different departments.

MES software:

Using manufacturing execution systems (MES) to manage and monitor the entire production process from raw materials to the final product.

Using production line management software can help improve efficiency, reduce costs, and increase product quality, and prevent many human errors.

Conclusion:

Using production line management software can significantly reduce human errors and help improve efficiency, quality, and productivity in production processes. These softwares play an important role in optimizing production by providing automation capabilities, advanced quality control, decision support, accurate inventory management, improved internal communications, and analysis and reporting.

Key benefits:

Reducing human errors: By automating processes and reducing manual interventions, the possibility of human errors is minimized.
Increased productivity: By optimizing the use of resources and accurate scheduling, production efficiency increases.
Improving the quality of products: Continuous quality control and implementation of strict standards leads to the production of higher quality products.
Better decision-making: Providing accurate and comprehensive data helps managers and employees make better decisions.
Accurate inventory management: Accurate inventory tracking and optimization of material usage prevents shortages and excess inventory.
Improved communication: Integrated systems and accurate information transfer improve internal communication.

Practical effects:

Production line management software can be used in various industries such as automotive, electronics, food and pharmaceutical manufacturing and help improve efficiency and reduce human errors in all these industries. In short, the implementation of these softwares is an important investment for any manufacturing organization that seeks to increase quality, reduce costs, and continuously improve.

Executive solutions:

Choosing the right software: analyzing the needs and choosing the software that best matches the specific needs of the organization.
Employee training: continuous and efficient training for optimal use of the software.
Gradual implementation: starting with small projects and gradually increasing the scope of software usage.
Feedback and Continuous Improvement: Collect feedback from users and continuously improve the software and related processes

The use of production line management software is a vital step in the direction of digitalization and intelligentization of production processes, which can bring long-term and sustainable benefits to the organization.