| When a major textile manufacturer
needed to provide consistent real-time and historical manufacturing information to its
global management, Synchrony stepped forward with a solution. Synchrony had recently completed an upgrade of their
manufacturing control system, including the addition of a centralized SCADA system that
writes manufacturing data to a SQL Server database also designed by Synchrony. While
performing the control system upgrade, both Synchrony and the manufacturers
management saw the need and opportunity to provide consistent reporting tools for status
and analysis. Historically any manufacturing reports were produced from incomplete
desktop databases. The data in these databases was often manually entered and report
definitions varied from manager to manager. The variance between reports could lead to
widely different strategic decisions.
A survey of
the custom reports in use by local management was conducted to determine what type of
information was desired and how it should be presented. In general two types of reports
were desired: current production status and historical performance. The current production
status reports would show how plant's performance at the current instant of time, processes
with excess capacity, processes requiring additional capacity, utilization of equipment
and employees, etc. Historical performance reports would be used as strategic analysis
tools. These reports should show which equipment or product causes problems,
production rates of operators, and would provide a means of tracking product history from
the original equipment through the plant to the customer.
After the survey of what tool
management would require from a web reporting system, Synchrony began developing the web
site. Standard templates were put together so that the reports would have the same look
and feel. Definitions were developed and approved so that terms such as scrap
and in production are used consistently throughout the entire system.
Filtering, sorting, and drill down schemes were configured so that the details required
for improving performance could be easily extracted from summary reports that illustrate
areas where improvement may be possible. And finally, a suite of web pages and navigation
tools were installed on the companys intranet making them available on
everybodys desktop.
Since the installation of this web
based enterprise information system, the companys management has at its fingertips a
consistent and well-defined view of their operation. Strategic decisions are now based on
a complete view of the operation. Every employee knows the performance of the facility,
their team, and themselves. Also, the framework allows new reports to be quickly
generated when requested.
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