MANUFACTURING
TECHNOLOGY
GUIDEBOOK

TAKE A BETTER ROUTE
TO WORKING LEAN

CONTENTS

A NEW PATH TO LEAN.

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There’s no room for waste in manufacturing. The competition is stronger than ever before. The most direct route to thriving is through a commitment to lean manufacturing.

One of the key objectives in Lean Manufacturing principles is to eliminate waste, which exists throughout the enterprise. But, before you can rid yourself of these excesses, you need to identify them.

OVERPRODUCTION

Producing more than you need creates excess inventory and the cost associated with carrying it.

WAITING

The downtime that occurs between production steps slows down your output. You produce less, ship less, and pay for labor that is unproductive.

TRANSPORTATION

Moving your materials and products through the production process is often a source of wasted effort.

OVER-PROCESSING

Products that are handled or worked on too many times create waste that needs to be addressed.

UNNECESSARY INVENTORY

The cost of carrying too much inventory includes capital expense, the accrued interest, and excessive floor space requirements. Conversely, working too lean with inventory impacts your production efficiency—costing you in downtime, rush shipping costs, and delays in order fulfillment.

EXCESS MOTION

Inefficient workflow results when your workers move around too much to complete their tasks.

DEFECTS

Raw materials and products that are rejected represent wasted materials and labor, as well as the negative impact on your production goals.

In this guide, we’ll help you identify the ways you can enhance your manufacturing operation. With the combination of lean manufacturing processes and the right technology, you’re on the path to success!

RUGGED VERSUS CONSUMER DEVICES: WHICH IS BEST FOR YOUR ENTERPRISE?

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device

We keep our personal mobile devices—smartphones, tablets, and laptops—close by, so it feels natural to cross over to using them in the workplace. In fact, Bring Your Own Device (BYOD) resulted from companies that recognized the ease and savings of having their employees come equipped with their own technology.

But do convenience and perceived cost savings outweigh the pitfalls of using a consumer device in the enterprise? Let’s look at the pros and cons.

DEVICE COST

A consumer smartphone has an enticing price tag, when you compare it to a rugged commercial-grade mobile computer. However, when you consider the long-term cost—not just the initial acquisition—you get a very different picture.

A consumer-grade smartphone lasts up to one year in a commercial environment, potentially less in a harsh environment, like a manufacturing facility. The price for the replacement device is dramatically more than the first one.

A rugged mobile computer that closely resembles today’s smartphones—like the Zebra TC55—costs more, but also lasts an average of three years, which provides a lower total cost of ownership (TCO) than the consumer smartphone. The rugged computer is designed to withstand the bumps and drops to concrete floors that would destroy a consumer phone.

Then, factor in that the average device failure generates 80 minutes of downtime per user, according to VDC Research. A more reliable rugged device eliminates this waste and sparks greater productivity. Just a 2% boost in productivity generates approximately $3,000 in annual savings, per worker.

IT SUPPORT

How many different consumer devices are your workers using? And how many different operating systems? Your IT team needs to support all of those. Each device must be provisioned before accessing your network. Then, there’s the management of the device, user, and apps. When a consumer device is connected to your network, all of the social media and personal apps are connected, too.

Your investment in IT support will also be diverted to helping employees with their personal devices when the personal use creates an enterprise problem, like the risk of a data breach.

ENTERPRISE-GRADE FEATURES

A rugged device is designed for use in the workplace. It features a higher grade of security, scanning capabilities (data, image, document capture), and device management. It integrates seamlessly into your ERP. A rugged mobile computer is a work tool. It doesn’t have social media, online shopping, funny videos, and other diversions that pose both productivity and security threats.

The choice of a mobile computing device based solely on the device price is not an accurate reflection of the actual TCO. Talk to us at Denali Advanced Integration to better understand the investment and its actual return.

GRAPHIC OF TC55 VS IPHONE 6 FROM PAGE 2 IN THE “SAMPLE TCO REPORT”?
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Material Flow Solution

OPTIMIZE PROCESS

Real-time visibility of material flow gives you the power to get LEAN.

SMART PLANNING

Insights into material usage permits intelligent inventory forecasting.

FLEXIBLE OPERATIONS

Multiple options to signal material moves give you flexibility at line side.

ELIMINATE 7 WASTES IN YOUR SUPPLY CHAIN

Real-time asset management is critical to successfully achieving your lean manufacturing objectives. Your strategy requires mobile technology that will enable workers to maximize their productivity and increase accuracy.

Zebra has developed numerous technology strategies to address seven sources of hidden waste in your manufacturing operation.

The Material Flow Solution, for example, enables manufacturers to centrally manage a lean replenishment process—eliminating disjointed, labor-intensive processes and enabling real-time data flow.
Here’s how it works:

  • 1. Line-side operators trigger material requests from their workstations by pressing the wireless WhereCall RFID button or scanning a barcode.
  • 2. The materials are delivered in an optimized priority system, reducing lag time and line stoppages.

The Material Flow Solution allows customers to maintain lower inventory levels at line side and in remote storage locations. It increases labor productivity and improves asset utilization via the real-time material requests that are fulfilled on a priority basis.

Zebra’s mobile technology—handheld computers, mobile printers, barcode scanners, RFID readers—improves the flow of information across the manufacturing processes. Wearable technology—wrist terminals, computer headsets, and ring scanners—maximizes productivity by minimizing motion. The rugged design and enterprise features of this technology reduce downtime and provide a greater range of functionality.

For more information on Zebra’s Material Flow Solution and mobile technology, contact Denali Advanced Integration.

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MOBILIZE THE PLANT FLOOR

How can you maximize your efficiency when your plant workers are running back and forth to access information, supplies, work orders, and everything else they need?

Zebra’s warehouse mobility solutions enable production workers to more freely connect with each other as well as the equipment. Better mobility allows for faster decision-making and problem-resolution—leading to greater accuracy and less downtime.

To improve workflow efficiency, your workforce needs to be agile. Rugged, handheld computers and vehicle-mounted mobile computers put the enterprise information, literally, at their fingertips. Your workers can access all of the data they need, like checking on machine status for predictive maintenance, and even accessing manuals at the sight of the repair They can transmit replenishment requests without leaving the production line, and enable Just-In-Time inventory balance. The mobility that this technology affords your operation reduces the waste that comes from unnecessary motion. The communication supports your goals of reducing excessive materials handling and the waiting time between processes. With real-time data, you can avoid overproduction by reviewing the most up-to-date inventory and sales figures.

Wearable technology continues to provide another source for elevating your operational efficiency. Wrist terminals, ring scanners, and computer headsets provide easy access to data, with ergonomic comfort that reduces conditions like wrist strain. Voice-directed solutions, like Zebra’s TekSpeech® Pro 4, streamline picking processes and reduce errors.

Mobility is a necessity on the plant floor. Denali Advanced Integration can show you how to determine the best solutions to achieve your goals.

line

PUT MORE DEMAND ON YOUR SUPPLIES

You know the saying, “Garbage in, garbage out.” Some products just are engineered and manufactured to achieve acceptable, not superior, results. If you have higher expectations, you need to make better choices.

This holds true for your thermal printer supplies. You rely on these machines to produce high quality barcode labels, RFID tags, receipts, and invoices—whether at your facility, in the yard, or on the road. The barcodes need to be scannable, even through all the loading and unloading that occurs. The costly downtime that results from lost or damaged labels or tags adds up fast.

Let’s also consider the wear and tear on your printer from inferior media and ribbons. The dirt and debris left behind can damage your printhead. Adhesive can ooze beyond the label and leave a mess inside your printer. The money you saved on the lower priced supplies will be needed to pay for printer cleaning, repair, and replacement.

Genuine Zebra Supplies are designed for very specific applications. With thousands of combinations of substrate and adhesive, the labels can be customized to your needs. From handling extreme temperatures, like cold storage, to resisting the tough conditions of loading docks and yards, Genuine Zebra labels will give you the durability and quality you should expect.

Denali Advanced Integration wants to help you identify the supplies that best match your printer and applications. Please contact us to learn more.

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DENALI MANAGED SERVICES PEACE OF MIND IS OUR SPECIALTY

Denali Advanced Integration provides a full range of value-added services that let you use our expertise to your advantage.

  • Kitting and Staging: Denali will order, receive, maintain, update, inventory, configure, provision, stage, store, and deliver your devices at your request, so they’re ready to run, right out of the box. We also maintain your replacement pool in our facility, and overnight the equipment as needed, saving you the time and cost of managing the inventory.
  • Deployment: We offer a broad set of options, combined with our experience in manufacturing technology, to provide a seamless, on-time experience for your operations. Our team provides the necessary documentation, on-site training, and ongoing remote support.
  • Managed Print Network: Denali’s technical experts can monitor and manage all the devices in your printer network. We oversee all maintenance schedules, replenish supplies as needed, and provide immediate response for repair. Managed Print Network services extend the life of your technology, conserve your in-house IT staff time, and cut down on the amount of downtime that occurs with printer management.
  • Managed Wireless: Put your network in Denali’s hands. We’ll ensure that the system runs smoothly, identify potential problem areas, and provide you with detailed reporting and analytics.
  • Service Desk and Field Support: Connect with a Denali support technician 24/7. Our skilled IT team can provide you with help desk support, troubleshoot network issues remotely, or dispatch a service technician to quickly handle the problem.

MANUFACTURING TECHNOLOGY SOLUTIONS PORTFOLIO

RUGGED AND ULTRA-RUGGED SCANNERS

Zebra’s high performance scanners handle the toughest challenges—from long read range to reading barcodes that are dirty, scratched, or even covered by shrinkwrap. Get the fastest read rates for 1D and 2D barcodes, images and DPMs, omni-directional convenience and long-lasting battery life—inside the most rugged casing in the industry.

  • tc8000

    3600

  • ds3508

    DS3508

  • ls3578

    LS3578

MOBILE COMPUTERS AND TABLETS

Zebra’s extensive portfolio of mobile computers and tablets handle every aspect of your enterprise computing needs. Along with the most durable devices in the industry, you get advanced security, data capture, connectivity, and device management capabilities as standard features in every Zebra mobile device.

  • mc3200

    MC3200

  • mc3200

    MC9500

  • tc55

    TC55

  • et50

    ET50

tc8000

The revolutionary design of the TC8000 features a single-plane interface that eliminates the tilt-and-verify motion and adds ergonomic comfort. The All-touch Terminal Emulation (ATE) transforms your legacy “green screens” into elegant, graphics-based screens that dramatically reduce the number of interactions to complete a task—yet another productivity booster. The TC8000 is 33% lighter than traditional models, increases productivity by 14%, `and reduces typing errors by 60%.

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WEARABLE COMPUTERS

Equip your workers with hands-free convenience and high-powered computing and exceptional voice clarity. Zebra’s wrist terminals, computer headsets, and ring scanners reduce unnecessary motion and improve accuracy.

  • wt6000

    WT6000

  • rs6000

    RS6000

  • WT41N0

    WT41N0

  • headset

    HEADSET

THERMAL PRINTERS

From the high-performance of Zebra’s industrial printers to the lightweight yet rugged mobile printers, Zebra’s advanced thermal print technology ensures reliable, quality printing for barcodes and RFID tags.

  • xi4

    XI4

  • ZT200

    ZT200

  • zd500

    ZD500R

  • zq500

    ZQ500

  • qln

    QLN

VOICE-DIRECTED SPEECH SOFTWARE

Maximize productivity with Zebra’s TekSpeech Pro 4 voice-directed software. The most advanced voice recognition engine delivers faster performance, superior accuracy, and greater control of speech functionality.

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PRINTER SUPPLIES

Reduce downtime and increase efficiency and compliance with high quality labels, tags, receipt paper, and ribbons for your thermal printer. Denali Advanced Integration carries the full line of Genuine Zebra Supplies to ensure lasting quality.

supplies

Denali

YOUR ENTERPRISE IT PARTNER

Denali Advanced Integration delivers Enterprise IT solutions and services, powered by strategic experts and best of breed technologies to help guide you through the most complex IT challenges.

Leverage our in-depth experience and expertise in mobile technology so you can focus on your business objectives.

Contact Denali for a consultation, product demonstration or just an informative discussion.