Written by

Seon Barbera

Published

April 21, 2015

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What Is Shop Floor Control and How Does it Drive ROI?

Shop Floor Control (SFC) is a software system of methods and tools that are used to track, schedule and report on the progress of work in a manufacturing plant. Shop Floor Control systems generally evaluate the portion of an order or operation that has been completed. That percentage of work in process is useful for resource planning, inventory evaluations [1] and supervisor and operator productivity on a shop floor.

Data Reported On By Shop Floor Control and How It Is Used

Shop Floor Control systems typically evaluate materials status, machine usage, labor and other resources to report on work in process [2]. They also enable the accurate management of activities, resources and work flows inside the plant [3]. This type of data can be very useful to manufacturing owners and supervisors for improving overall shop floor operations, particularly with an interactive, real-time Shop Floor Control system.

Data gathered and reported on by a Shop Floor Control system regarding labor, work progress and production time can also increase worker productivity, reducing throughput and cycle times. In addition to delivering worker productivity information to supervisors, real-time Shop Floor Control can be useful to the operators themselves. Giving operators access to their own work process empowers them to set, meet and exceed their targets and goals. With an incentive system in place, operators are further encouraged and motivated to meet those targets and goals, thus improving performance and overall plant productivity.

How Shop Floor Control Reduces or Eliminates Risk in a Manufacturing Plant

Shop Floor Control systems can help identify risks and vulnerabilities in the shop floor environment, from technology and machine issues to employee-related or labor concerns. With a real-time Shop Floor Control system in place, manufacturing plant owners and supervisors are empowered to realize a proactive environment where they are able to identify, adjust and resolve issues as they occur or even before they arise, as opposed to the run-of-the-mill batch shop floor control systems that limit users with retroactive data and reporting.

Factory Conditions: Accountability and Responsibility with Shop Floor Control

In today’s social climate, light has been shed on many regrettable factory conditions around the globe. Even manufacturers who are diligent about going above and beyond all regulations and compliance are keenly aware of the concerns. Shop Floor Control systems are uniquely able to help address these concerns within a plant, ensuring that all social and labor compliance issues are met. Shop Floor Control is designed to monitor, track and report on labor-related compliance, giving operators, supervisors and owners alike peace of mind.

How Shop Floor Control Drives ROI

The ROI of implementing a Shop Floor Control system is manifest in improved productivity and production as well as more accurate, efficient, streamlined operations. Shop Floor Control saves and optimizes time and reduces waste. Some of the Shop Floor Control benefits that drive ROI:

  • Total visibility and control over plant environment
  • More efficient, streamlined operations and lowered manufacturing cycle times
  • Data-driven, higher quality production
  • Greater supply chain visibility
  • Immediately actionable, proactive data and analytics when employing a real-time SFC system
  • Empowered supervisors and managers
  • Increased operator motivation, productivity and performance
  • Improved accuracy in reporting on resource status, work flows, inventory and human resources
  • Accurate updates on labor and machine usage
  • Improved scheduling and planning
  • Improved valuation and costing capabilities
  • Reduction of excess labor costs
  • Reduction of payroll computational errors
  • Reduction of work in process inventory

With Shop Floor Control software, manufacturing supervisors can monitor the full breadth of shop floor control activities and make better, more informed decisions immediately – while there’s still time to correct problems and improve the operations that drive bottom line results.

 

To learn more about real-time Shop Floor Control, please visit: http://www.cgsinc.com/en/bluecherry/shop-floor-control.

 

References

[1]

Gartner, "IT Glossary | SFC (shop floor control)," [Online]. Available: http://www.gartner.com/it-glossary/sfc-shop-floor-control.

[2]

Siemens, "Manufacturing Shop Floor Control," [Online]. Available: http://camstar.industrysoftware.automation.siemens.com/en/resources/glos....

[3]

Oracle, "JD Edwards World Shop Floor Control - Process Guide," [Online]. Available: https://docs.oracle.com/cd/E26228_01/doc.93/e21780/ovr_shop_fl_ctrl.htm#....