The Manufacturing Costs of “Business as Usual”

The Manufacturing Costs of “Business as Usual”


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The cost of doing nothing to ensure solid processes in manufacturing.

Quality is more than just an end product; it’s the means and methods to get you from point A to point B. Bluestreak works to take business as usual and improve the process through real-time improvements. Quality data is collected directly from the manufacturing floor with the ultimate goal of reducing manufacturing costs. Tracking is vital for improvements, and with Bluestreak, it becomes seamless. In order to know where you’re going, you have to know where you are. Tracking manufacturing processes and costs identifies a starting point upon which to build continuous improvements.

Re-work costs money. Rejected product costs money. Non-conformance or client dissatisfaction costs money. Manufacturing costs are directly related to the goal of client acceptance of a high-end quality product the first time. The means and methods to reach that goal can be achieved through the use of Bluestreak work order management, specifications, all-inclusive quality control plan (implementation and long-term management), and production scheduler. With control of the process from start to finish, tracking documentation straight from the manufacturing floor, the advanced levels of awareness identify where improvements can be made for an ultimately streamlined process and exceptional quality assurance. For every step in the manufacturing journey where a problem is left unnoticed, the longer it will take to correct it or the higher chance that the product will be disposed of. If correction is not possible, you want to be able to dispose of the item quickly, before more time, materials, and labor are used on a product that cannot be used. Even if a correction can be made, the longer it takes to identify, the more expensive the fix.

Quality control is the delivery of a quality end product, whereas quality assurance is how to get there. Bluestreak guides you through manufacturing floor processes and improvements toward quality at every step, decreasing rework and increasing profitability through reduced manufacturing costs. When a defect is identified immediately, it can be fixed immediately. Quickly identified defects that are corrected on the spot prevent product from moving to the next step in manufacturing. Through Bluestreak tracking, you can go above and beyond removing a defect. You can identify the criteria around the defect and use that data to prevent it from happening again. For example, if you made a casserole at home and left it in the oven so long that it burned, you wouldn’t do that again—you would use the information of your mistake to improve the next round. That’s the same thought behind tracking real-time data for the identification of when a defect occurs. If you did nothing during all manufacturing errors, the cost of continuing business would never decrease and would even potentially increase as mistakes and defects keep occurring. Doing nothing will ultimately cost you more. While tracking, analyzing, and improving the process may have an upfront investment, overall manufacturing costs will decrease.

Bluestreak focuses on processes, not inventory, driving to the root cause of non-conformance through data visible any time, anywhere, from any device. With all data collected and maintained in various modules and presented in BlueCharts, the results are clearly defined. Employees and contractors are overburdened with increased organizational complexity and stringent red tape. Simplifying the process helps ensure that everyone works together with the same goal in mind, so you can reach the quality you need.

We cannot improve by just doing what we always do; we need to utilize the data collected to make the appropriate changes. When we do nothing, we waste money and increase manufacturing costs. Improvement starts with tracking data through Bluestreak and monetizing the value of the process. A centralized tracking platform simplifies each step of the way for all levels of participants to do their part. From each worker on the floor to supervisors and management, visibility throughout the process keeps a finger on the pulse of manufacturing costs from start to finish.

If you’re ready to leave manual, time-consuming service-based manufacturing tasks in the past, drastically reduce your scrap and rework percentage, gain visibility of your production floor processes, and build better relationships with your customers, contact us for a free consultation today!