Background

  • The existing MES (Manufacturing Execution System) managed production performance for each process of the assembly line.
  • However, in departments like Mold and Press, which handle parts manufacturing, the MES struggled to manage production performance of input parts effectively.
  • Thus, a separate system was needed to manage equipment and production parts.

Development Details

  • Development Period: March 2014 – December 2014
  • Platform: Windows XP, 7, 8
  • Technologies Used: Delphi, Oracle PL/SQL
  • Delphi was used for front-end screen development.
  • Business logic was implemented in PL/SQL.

Education and Technical Support

  • Conducted training and provided technical support for on-site managers.
  • Created and conducted training sessions on the program’s user manual for on-site workers.

Key Archivements

  • Digitization of Production Performance: By digitizing previously manually recorded production data, accuracy increased by 20%, and work time was reduced by 50%.
  • Equipment Operation Management: Provided data to help managers create production plans for each piece of equipment.
  • Mold Process Improvements: Inputting material usage data enabled real-time monitoring of remaining materials, reducing the risk of shortages by about 20%.
  • Press Process Enhancements: Tracking intermediate production performance led to a 10% improvement in inventory accuracy.
  • Worker Efficiency: Digital input of performance by each worker streamlined labor management, reducing labor management time by 30%.

 

Overcoming Challenges

Digitizing manually recorded production data was no easy task. A key focus was identifying what the managers needed and understanding what issues they faced. Additionally, many on-site workers lacked basic PC skills, making training difficult initially. To address this, we designed a user-friendly interface where workers could enter data by pressing just a few buttons, contributing to a smooth transition to digitized production management.

I vividly remember the joy I felt seeing workers use the system and managers benefiting from increased efficiency through digital performance management. Reflecting on this experience, I’m proud of how we met customer needs and directly contributed to improving their processes. Although my recent roles have involved less direct interaction with clients, this project remains a fond memory, and it’s something I would love to experience again.