Vortex is a software embodiment of the patent-pending technology developed for high-mix, non-repetitive manufacturers as an outgrowth of the DeHart Consulting LLC Lean Manufacturing methodologies. Using the ground-breaking technology embedded in this Lean Shop Floor Control System as an add-on to an existing ERP system, expect 2 - 10x improvements in WIP and cycle time. In addition, because the Vortex demand-pull manufacturing system is completely algorithm-based, it also supports a machine learning system that will further improve your results over time. With the advent on the Industrial Internet of Things (IIoT) and Industry 4.0, forward thinking companies are increasingly digitizing their production execution systems. Vortex provides that opportunity to the high-mix manufacturer.
Our goal is to bring the same revolutionary improvements that the Kanban demand-pull system brought to the automotive, and other repetitive, manufacturing industry into the reach of producers with more complex workflows. Until now, demand-pull production, one of the key tenets of Lean Manufacturing, was inaccessible to non-repetitive discrete product manufacturers and semiconductor fabrication facilities because Kanbans just don't work well in this environment and the available shop floor control systems had no features available to support a pull system. But the Vortex demand-pull manufacturing system changes all that by pulling work within the factory based on flow time instead of unit-replenishment. Please take a look at the video below and then call or contact us for a discussion, demo, and/or an integration proposal.
Vortex Lean Shop Floor Control System - View Text of Video
Since the early 1980's, the benefits of producing a given production volume throughput with the minimum amount of inventory have been well documented. Beginning with the Just-in-Time methodologies, using Kanban cards for inventory replenishment, to Demand Flow methodologies,
Read more: DCI Introduces Vortex Demand-Pull Technology
The time-based demand-pull system (“demand-pull system”) technology of the described demand-pull system provides an implementation of demand-pull scheduling for various production operations/systems/factories. It works in conjunction with a Material Resource Planning (MRP) or Enterprise Resource Planning (ERP) system, which creates production WOs and houses associated data, such as workflows and operational standard hours, to pull work through a factory with results similar to that of POLCA.
Read more: Vortex Introduction
When looking at work flow through a factory from the perspective of minimizing cycle time and honoring demand-pull policies, work should be processed on a first authorized, first processed (FAFP) basis. In other words, once a WO has been authorized within a WC’s queue, it should be pulled into production on a FAFP basis. Deviating from this policy can result in an increase in the average cycle time, unless batching of WOs will reduce their aggregate cycle times due to machine capacity. For an example of the latter situation, a machine may be capable of simultaneously processing ten pieces, and if there are two five-piece (or fewer) WOs, they could both be processed at the same time to reduce their aggregate cycle time, improve efficiency and maximize capacity.
Read more: First Authorized - First Processed Work Flow
From a flow-time perspective, Work Orders should arrive in a Work Center's queue at precisely the time when they are needed to be worked on. This minimizes both production cycle-time and inventory investment. The desired time for the next WO to arrive for processing is when the currently-authorized work in a WC and its upstream-adjacent (UA) WCs has been started into the WC and cleared the first operation in the WCs routing. This assumes that demand exists for the WO at the next downstream work cell.
Read more: Demand-Based Production from a Flow-Time Versus Need-Time Perspective