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Cost Control Solutions

Manufacturing a product takes time and money. You have to invest in the right type of equipment that will be able to help you create a product and you must also spend time researching the best suppliers to work with in order to acquire the materials you need to manufacture the products you need. Cost accounting is a very simple procedure when you understand how to do it. What does cost accounting do? It will uncover all of the unnecessary expenses that your company has. You can quickly find out what your overhead costs are and you will be able to determine how to minimize your costs with certain areas. Reviewing your financial records will allow you to also see where the overhead costs are.

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Understanding quality control and quality assurance

When you purchase a product or service you expect a high level of value. Your customers expect this same thing from your organization. Since standards are so high on organizations, it is easy to see why you need to worry about quality control and quality assurance within your organization. Quality is the key to any manufacturing company's success and you need to seek out methods that will be able to help you maintain a higher level of quality. In most cases this means turning to a system like lean manufacturing or Six Sigma to help you improve the organization. Your customers deserve and want nothing short of the best so it is your responsibility to give this to them. Let's look at what quality assurance and quality control mean and how they can help to improve your organization.

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Six Sigma training applications

Six Sigma was invented in the manufacturing industry by Motorola. Six Sigma focuses on reducing waste by getting your error ratio to 3.4 defects per million products produced. Implementing Six Sigma may take some time before you are able to implement it right and have all of your employees embrace it. There are a number of Six Sigma training applications you can use in order to learn about Six Sigma and to also implement it into your organization.

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How to reduce product defects

businessmeeting33030005.jpgReducing product defects needs to come from within the company or organization that is creating the product. Utilizing Six Sigma or other process improvement strategies can help you eliminate product defects. Reducing product defects will help to increase productivity; costs will lower and will help the company save money. Using your employees will help keep their morale high and will show them that you believe their opinion really matters. When you keep your employees involved you will see a vast improvement on product. Less errors and mistakes will happen, which will lead to lowering your product defects.

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Dealing with waste in lean manufacturing

janitor37426736.jpgLean manufacturing focuses on the elimination of waste. Waste is anything that does not add value to the company. In order to start eliminating waste, you must be able to identify it first. Take a look at your processes and check for inefficiencies and redundancies. One way to look for waste is to listen for it. While this may sound strange, it actually works.

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The basics of manufacturing standards

pushups63329537.jpgA standard is a something that is measured against.In school, we are measured against academic standards and given a grade that reflects our standing when compared to that standard.In manufacturing, there are standards of operation and management.These standards are generic, meaning that they apply to all manufacturers and business owners no matter the size or nature of the organization.The business can be a public, private or even government entity and the generic standards would still apply.

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Identifying hazardous waste

coastalplant36588209.jpgAs a manufacturer, you should already be aware of the fact that you must dispose of your hazardous waste in a proper manner. If you fail to properly dispose of any hazardous waste, your manufacturing business can be fined a large amount of money. Getting g rid of hazardous waste properly is important because of the harmful effects that hazardous waste has on the environment and some of it can be harmful to people's health.

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The advantages and disadvantages of Six Sigma

concernedman19185284.jpgImplementing any kind of manufacturing process is a very important decision for your business and should never be treated lightly.Many companies choose to use a particular method because it is the latest trend or because competition is doing it.But weighing the advantages and disadvantages for your business is one of the most important steps you can take to feel right about your decision to implement Six Sigma or not in your own business.

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Using visual control


Visual control is a method used to make jobs easier by using visual signals. Some companies use lights, colored cards, colored clothing, to any method that communicates a need for a decision to be made. Kanban and heijunka boxes are commonly associated with visual control.

Visual control helps to replace the need for text with a visual image that quickly sends the same message. To think of visual control, open a tool box that has plastic slots for each tool.

The tool normally has a silhouette of where it to be placed. Without reading anything or saying anything, you automatically know what tool is missing.

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Distributed control system


A distributed control system (DCS) refers to a control system that is usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like a brain center) but are distributed throughout the system with each component sub-system being controlled by one or more controllers. The entire system of controllers is then connected by networks for communication and monitoring.

Distributed Control System is a very broad term that is used in a variety of industries, to monitor and control distributed equipment. Some of these are:

  • Electrical power grids and electrical generation plants

  • Environmental control systems

  • Traffic signals

  • Water management systems

  • Oil refining plants

  • Chemical plants

  • Pharmaceutical manufacturing

  • Sensor networks

  • Dry cargo and bulk oil carrier ships

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PLC process control

Have you ever wondered how measurement devices such as thermostats work? How does the thermostat measure the room temperature and then make the necessary changes so that your furnace or air conditioner suddenly turns on or off? This would seem to be an almost magical process. Thanks to brilliant engineers working for years we now have what are known as programmable logic controllers (PLC) that measure and adjust machines, and many different types of machines. Beyond your PLC thermostat there are very important applications for a PLC in manufacturing. As you can imagine, there are several complicated processes that use a PLC to monitor and change the way that they work. Think about a manufacturing process, for example, that requires some sort of raw material input. If the inputs came to frequently or not frequently enough the process can encounter serious problems. Things at both the input and output end of the production line need to be closely monitored in connection with each other.

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DCS Process control

Have you ever wondered how complex industrial or electrical systems are monitored? Take, for example, something like a chemical manufacturing plant. How does one part of a system know that another part has completed its assigned task? Is there some central brain that controls all of the processes at once? These sorts of systems seem almost too complex for most of us to investigate or figure out. It does actually take engineers years of training to design complex process control systems. Some work according to a single programmable system control that takes in information and makes changes according to a set of logical systems. By this means a complex manufacturing process can be controlled and changed according to certain needs of the situation. However, these sorts of programmable logical control devices are extremely important for simple manufacturing, but there are other processes that require a more complicated system. For example, systems that have many different processes going on at once need several different controllers. They may need a different controller for each one of the processes and each one of those controllers would also need to communicate with each other because they have to funciton in order.

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