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Work in Process

Usually there are three stages of manufacturing i.e.  Raw material, work in Process and finished goods

Work in Process usually includes the following components:
- Components
- Assemblies
- Semi finished goods/ products
- Assemblies waiting period between work centers

It is natural to have a need of WIP buffers between manufacturing operations in order to minimize the possibility of shortages.

Process Bottleneck

  • Keeping a higher buffer of WIP brings its own set of disadvantages for the organization which has a direct bearing on the financial performance of the company.
  • More capital tied up in WIP thus incurring excessive interest cost
  • Higher occupancy costs (rent, Insurance, heat, light, taxes, etc)
  • Larger quantity of product to rework if problems are found or design changes occur
  • Poor visibility of quality problems
  • Poor responsiveness to changes in the production schedule
  • Greater exposure to obsolete inventory costs

Solution on Offer

Intellicon offers WIP solution using Automatic Identification and Data Capture Technologies for effectively tracking the flow of material, assemblies and products. The entire barcoding set up can help the organization reduce the WIP requirements and also reduce the scope for human intervention in the day to day operations.

  • Each work center has a barcode scanner which in turns is connected to the PC.
  • Each product or assembly  carries bar code which is scanned as is passes through various stages of the process
  • Assuming that there may be a case for the product to be minuscule in size,  a work order accompanies the product on assembly with a barcode on it.
  • All the operations can be listed and further scanned after they are carried out at various stages.
  • Word order no , operation ID and employee ID are scanned when the process is over.

Key Benefits of the Solution

Automation of Data Entry:
Our Solution eliminates Manual entry of data at every point of Data Collection

Improved Efficiency:
Increase in efficiency of the employees due to Automatic Data Capture and hence reduced processing times

  • Rejections and rerouting can be tracked here
  • Employee deficiency can be tracked\
  • Inventory on shop floor can be tracked and minimized
Elimination of Data Entry Errors:
Automatic Data Capture reduces errors in data entry hence the overall system becomes more effective leading to an efficient WIP at the organization
  • Reduces Malpractices
  • Better quality control
  • Reduced communication cost
MIS Reports
Data collection network time stamps each transaction and up dates data base. This data can be  used to generate various MIS reports for:
- Material requirement planning
- Work order status.
- Work in process levels.
- Bottlenecks
- Productivity
- Yield