Author Archives: USCCG

In Gartner’s latest report “Top GenAI Use Cases That Work Best for Supply Chain Logistics,” Carly West and Jose Reyes highlight the transformative impact of generative AI (GenAI) on supply chain logistics.

The key findings from their research indicate a widespread exploration of GenAI, with nearly 100% of supply chains investigating its potential to improve operations.

Additionally, organizations are dedicating an average of 6% of their 2024 budgets to GenAI technologies, underscoring the significant investment in these advancements.

Furthermore, 65% of organizations are creating new roles specifically for generative AI expertise, reflecting the need for specialized knowledge to leverage these technologies effectively.

Generative AI and Key Use Cases

Generative AI, supported by foundation models trained on vast datasets, offers numerous applications within logistics. One prominent application is content creation, which includes drafting KPI scorecards, creating standard operating procedures (SOPs), and generating essential documents such as shipping forms and RFP templates. Another key use case is information discovery, where AI aids in KPI analysis, supplier performance diagnostics, and managing shipment inquiries, thereby streamlining processes and enhancing decision-making support.

Generative AI excels in summarization tasks, efficiently summarizing meeting notes, reports, and customs documents, which helps in managing large volumes of information. In transportation and warehousing, AI-driven solutions facilitate predictive maintenance, enable autonomous systems for robotic picking and document processing, and provide real-time customer assistance, contributing to more efficient and reliable operations.

Implementation Considerations and Challenges

For successful AI implementation, it is crucial to assess the feasibility and business value by evaluating talent availability, technology readiness, and data quality. Effective data governance is also essential, as organizations with well-managed data report more impactful business outcomes. However, data-related barriers such as accessibility, quality, and complexity remain significant challenges that must be addressed. Furthermore, by 2027, 50% of large organizations are expected to reevaluate their data governance to handle complex, data-driven use cases effectively.

AICA’s Role in Addressing Opportunities and Challenges

AICA specializes in product and service data cleansing, enrichment, creation, and comparison, leveraging advanced AI and ML algorithms to detect and rectify errors in datasets.

Enhancing Data Quality and Consistency

AICA’s data cleansing and enrichment services ensure high data quality, crucial for leveraging GenAI in logistics. They address data inconsistencies and quality issues through robust data cleansing processes, including deduplication and anomaly detection.

Facilitating Data Integration

Modular design supports the seamless integration of diverse data sources, aligning with logistics’ needs for unified data systems. AICA’s data normalization services enable standardized data formats for efficient processing, overcoming integration difficulties.

Strengthening Data Governance

Data governance framework establishes clear standards and accountability, enhancing AI readiness. Their domain-specific algorithms ensure compliance and data integrity, helping organizations navigate data governance challenges.

Supporting Multilingual and Localization Needs

Multilingual translation capabilities support global logistics operations, making data accessible across languages. AICA is able to overcome language barriers and localization issues with precise translation and cultural adaptation of data.

Enabling Advanced Analytics and AI Use Cases

AICA utilize AI-driven insights for advanced logistics analytics, including predictive maintenance and KPI diagnostics. Their comprehensive data management solutions enhance model accuracy and reduce bias, tackling AI implementation barriers.

Enhancing Operational Efficiency

AICA leverage AI solutions to automate routine tasks and improve logistics efficiency, aligning with GenAI’s potential. Efficient data processing capabilities address time constraints and resource allocation, allowing teams to focus on strategic initiatives.

Why Choose AICA?

AICA’s solutions are up to 90% faster than traditional methods, significantly reducing the time needed for data management tasks. Their AI-driven approach reduces the need for manual labor and minimizes errors, cutting down on operational costs.

AICA’s specialized Large Language Models (LLMs) achieve over 80% accuracy, far exceeding the 30% accuracy of general AI models. Their algorithms are specifically trained on MRO product data, ensuring highly relevant and precise data handling.

Furthermore, AICA’s services are highly customizable, allowing you to select specific solutions that address your unique data challenges.

In conclusion

AICA’s advanced AI and ML solutions are well-positioned to help organizations navigate the complexities of integrating generative AI into supply chain logistics. By addressing data quality, integration, governance, and operational efficiency, AICA ensures that organizations can fully leverage the transformative potential of AI in their logistics operations.

We would like to thank and reference Gartner for the information referenced in this article.

*This article is written by USC Consulting Group’s strategic partner in data cleansing and management, AICA. For more information how AICA can cleanse and enrich your product and services data with AI, visit their website.

Back to top ↑

The manufacturing industry is experiencing multiple challenges this year. Among the most significant hurdles it’s facing is a high turnover. Roughly 75% of the manufacturing professionals surveyed by L2L reported a lack of skilled workers in the sector over the past 12 months, fueled by poor communication and management skills. That triggers a domino effect that can impact a manufacturing company’s ability to run smoothly, meet changing consumer demands to attract and convert leads, scale operations—and, ultimately, bolster its bottom line. This makes increasing sales and revenue arguably the biggest problem the industry is tackling today.

But how do you solve it when profit is also the one thing that will help you invest in the necessary solutions? Insights from the L2L report believe the answer lies in digital transformation. With the right revenue-boosting tools, manufacturing businesses can take advantage of a few key benefits that can help increase their profit margins and face the above challenges head-on. Here’s more on the value revenue technology can bring to the manufacturing industry.

It streamlines revenue recognition

Tracking income streams can often be more challenging in manufacturing compared to other industries. Businesses in this sector usually offer a more diverse range of products and services to cater to unique client specifications. That means production cycles in manufacturing typically take longer than average. Due to these factors, juggling multiple client contracts and receiving payment at irregular intervals is typically the norm for the manufacturing business. That can complicate revenue recognition, which involves recording and reporting all income a company generates in line with industry regulations and accounting principles. Revenue technology can streamline the process, making it easier to track all sources of income, more accurately assess a business’ financial health, forecast future revenue, and budget accordingly.

That’s why you’ll see even major manufacturers like IBM using the revenue recognition software on SOFTRAX. This multi-tenant solution uses back-office automation to recognize revenue for you in compliance with ASC 606 and IFRS 15, even if you use complex billing models. That way, you can practice continuous accounting no matter how many clients you’re handling and what kind of product they’re asking for. Automated revenue recognition solutions also free up employee resources for more valuable tasks, which can help hit multiple birds with one stone—they’ll have time to strategize on how to increase revenue further, and that can challenge their skills, enhancing job satisfaction for reduced turnover.

It enhances debt recovery capabilities

Despite the value technology brings to revenue recognition, the same factors that complicate the task of tracking income can make collecting payments from clients more challenging. The lack of communication mentioned above can often extend to clients, making overdue payments one of the biggest sore points that add tension to customer-supplier relationships. That’s why business development experts from Krem Energy find that manufacturing has the second-highest rate of overdue payment rate out of any industry, with companies often waiting an average of 32.8 days for compensation. This issue can significantly impact cash flow, which is why you’ll want to have a plan in place to deal with it. That’s where revenue technology can help.

With the right platform, you can automate everything from communicating with clients about overdue payments to ultimately collecting them. Vergent’s loan management software, which is used by leading lending firms like TMX Finance, illustrates how those benefits can apply to manufacturing. Though not originally designed for this industry, it offers automated collection services to facilitate smooth debt data and money transfers for streamlined recovery processes. It also provides the ability to customize client communications, which can be especially useful for manufacturing businesses with a diverse customer base. Automated tools like this one can reduce operational costs usually spent on debt recovery for improved savings, while also helping the employees typically assigned to this task focus on more pressing responsibilities.

It improves cash flow

The above benefits mean manufacturing businesses can ultimately use revenue technology to boost cash flow. That’s important because increased profits allow companies to invest in solutions that can answer multiple industry challenges and keep operations sustainable in the long run. For example, funding employees who want to take online classes from sites like Coursera can help upskill existing workforces to make up for labor and skill shortages, while ERP management software can pay for itself by streamlining inventory and project management for improved operations. More income also means businesses can refer to consultants to determine exactly what’s causing financial inefficiencies and receive tailored help implementing changes, which is precisely what we offer here at USC Consulting Group.

One great example of this can be seen in our case study, which outlines how we helped one of our clients—whose services specialized in moving equipment—increase cash flow. Our consultants first pinpointed a disconnected floor plan as the main issue, as it caused a lot of unnecessary travel for workers retrieving materials. They then implemented ways to eliminate redundancies. A major part of the improvement project? Creating a new floor plan in line with input from experienced employees. The client benefited from a 91% to 115% jump in efficiency, all while cutting down on the necessary manpower and expenses needed to make that happen. Revenue technology helps pave the way for manufacturing businesses to gather the funds needed to avail of these customized solutions, which is arguably where they provide the most value.

*This article is written by Rose James. Rose is a freelance writer with almost a decade of experience. She writes about new developments in business and finance, as well as on new technologies like AI and automation.

Back to top ↑

Manufacturing can be a competitive industry. You not only need to produce innovative products that capture the market. It’s also essential to run efficient operations to keep your margins healthy. One of the elements that helps you achieve both of these is a high-quality workforce.

When your employees have the resources and skills to maintain high performance levels, you have a powerful tool to meet your company’s goals. Indeed, with continual development and nurturing, the group of professionals you cultivate can contribute to your successful growth. It’s well worth looking closer at some strategies that help you hone your workers into cohesive and productive teams.

Prioritize Communication

Any manufacturing enterprise features a range of professionals. One of the elements that helps this disparate workforce to function as a unit is solid communication. If there are hurdles to interactions, your workers are likely to be less efficient and less able to overcome challenges. Therefore, focusing on designing and implementing communication protocols is a key to better-performing teams.

The most straightforward protocols you can adopt are those that make communication easy and convenient for all staff members. This begins with establishing channels that offer multiple methods on a single platform. For instance, tools like Slack and Microsoft Teams enable staff members to direct message (DM) each other, have audio calls, and hold video conferencing all on an app they can store on their phones or computers. As a result, they can keep in regular contact with all colleagues present on the platform.

Another good step is creating an accessible organizational chart. This outlines the personnel in each department, their place in the hierarchy, the skills they have, and the best ways to connect with them. Having images of each also supports recognition when moving throughout the production floor and break spaces. Placing these org charts in each department and storing them on cloud platforms empowers workers to know who to contact whenever they need help or have questions.

You must also make it easy for workers to communicate their opinions to company leaders. Employee feedback can enhance performance by highlighting areas for practical improvement. When workers see their insights are appreciated and actioned, there can also be greater engagement and trust, which feeds into positive outcomes. Manufacturing managers need to actively reach out to staff of all levels to gain feedback, both in conversations and using surveys. Your company can also make open feedback channels available on the intranet or aforementioned communication apps.

Optimize Operations

It’s difficult to cultivate high-performing manufacturing teams if there are elements of their working processes that present hurdles. Investing in methods to optimize different aspects of your operations is essential. These enable you to develop an environment that empowers your workforce to function at its peak.

Technology plays an important role here in various ways. Some of the tools that enhance optimization include:

Data analytics

Having a thorough understanding of how efficiently each element of your business is running is central to making informed operational adjustments. There are cloud data analytics platforms on the market that track the metrics of all aspects of your manufacturing operations, from staff behavior to the waste your production processes generate. You can further optimize this by placing devices in the Internet of Things (IoT) throughout your facility, so that embedded sensors can collect accurate data to share with your analytics tools.

Automation

The manufacturing industry has long embraced automation. However, it’s important not to simply limit it to dangerous or precision production processes. You can also consider automating certain administrative and management tasks. Many repetitive parts of jobs, like data entry, invoicing, and inventory management can be performed by artificial intelligence (AI) driven software. This optimizes your human staff’s available time, enabling them to concentrate on more complex parts of the business.

Remember, too, that investing in your staff’s development is also a vital optimization practice. Training levels up your workers’ skill sets, allowing them to operate more efficiently and innovatively. Your investment also makes workers feel valued, which may boost their connections with your business, which can drive their productivity.

Encourage Collaboration

While each employee is an individual professional, developing cohesive teams is key to high performance in manufacturing. When you establish protocols and tools that encourage positive collaborations, there’s the chance to generate results from the collective that you wouldn’t get from individuals alone.

For instance, during the ideation phase of projects, using mood boards can offer opportunities for teams to work together on a shared creative document. These materials involve the team contributing images, colors, and even text to evoke the emotions around the project and spark concepts that lead to the final product. When you make digital mood boards stored on a cloud platform, you can empower different members of the team to provide contributions, no matter what department they work in or even if they’re operating remotely. It helps everyone to feel a meaningful part of the business and maintains team cohesion.

Wherever possible, arrange for members of each team to engage in collaborations with diverse populations of professionals. Cross-departmental projects and even fun team-building activities give your staff chances to work with people outside of their usual circle. This exposure to different perspectives and experiences with people of different abilities, seniority, and cultures can be a vital source of development that boosts future collaborations and innovations.

Conclusion

Building high-performing manufacturing teams influences your success. Your efforts should include a range of measures, from protocols that bolster communication to adopting tools that optimize working practices, among others. Don’t forget to seek your workers’ feedback on this matter, too. They are likely to have keen insights into what hurdles to performance are in their jobs and how to overcome them.

*This article is written by Ainsley Lawrence. View more of Ainsley’s articles here.

Back to top ↑

Got Gen Z on the payroll? If you’re like many companies in the manufacturing sector, the answer is likely “no.” That is a talent pipeline your business is missing out on. A couple of recent studies highlight the scope of it.

Here’s a snapshot:

• By 2030, Gen Z will make up 30% of the U.S. workforce. The seasoned pros and top employees you have now will be looking at retirement if not already out on the golf course full time.
• 70% of Gen Z would NOT consider a career in mining.
• 48% of Gen Z now working in manufacturing intend to leave their jobs within the next three to six months.
• 71% of mining executives said the talent shortage is now affecting their delivery, production targets and even strategic objectives.
• 86% said it’s more difficult to recruit and retain talent.

Despite these rather bleak statistics, there’s good news out there, too. It’s possible to turn those numbers around with some savvy strategies for hiring and retention.

Gen Z: The Toolbelt Generation?

The first step in attracting the younger generation to your workforce is knowing what makes them tick. Who are these kids?

Born between 1997 and 2012, Gen Z is digitally native, meaning they have never known life without a cell phone or the internet. They are extremely socially aware and environmentally conscious.

Gen Z grew up during the pandemic. These are the students who couldn’t go to their high school proms because of Covid-19 and discovered the realm of virtual learning.

Gen Z values work-life balance more than money, and are interested in career growth. They have heard about the crushing burden of student debt all of their lives, and the good news for manufacturing, Gen Z is trending toward trade schools rather than getting an expensive four-year education.

In fact, the Wall Street Journal just ran an article titled “How Gen Z is Becoming the Toolbelt Generation.” And it’s getting a lot of buzz.

The article highlights a growing trend of young people opting for trade schools over four-year college degrees. The reasons are as pragmatic as Gen Z itself:

• Student debt. They don’t want it.
• Immediate employment. They’ve seen their older siblings struggling in a tough job market.
• Changing perceptions about “the trades.”

6 tactics to attract Gen Z

So, what are some strategies to attract this younger generation?

Emphasize work-life balance. Gen Z is all about their work-life balance. That means flexible hours, competitive compensation, great benefits, and a healthy amount of vacation time.

Highlight problem solving. Gen Z loves to problem solve and put their minds to work.

Showcase high tech. Manufacturing organizations are leaning into tech jobs, with robotics, and data analytics. Showcasing these aspects of the industry will appeal to young digital natives.

Outline a career path of growth, development, mentorship and training. The last thing Gen Z wants is a job with no future. These young people need to see how they can grow and develop within your company, that there is a path forward and training to help them get there.

Partner with trade schools… Trade schools are your pipeline for new employees, so sponsoring a job fair, speaking to classes, and otherwise developing a presence at your local trade school will put your company top of mind when these young people graduate.

…or pay for them to get the training they need. An alternative or even complimentary strategy is recruiting students right out of high school or online with the promise you’ll pay for their degree. If families are wary of student debt, this can be a powerful motivator.

Attracting and retaining Gen Z can feel like a moving target. But by focusing on what’s important to this generation, you can zero in on an enormous pool of talent that will take your company into the future.

Back to top ↑

The world is increasingly focused on sustainability, and the manufacturing sector is no exception. Consumers are demanding eco-friendly practices, and regulations are evolving to reflect this shift. This presents a compelling opportunity for manufacturers – by incorporating sustainability principles into the design of their machines, they can not only benefit the environment but also reap significant economic rewards.

The Benefits of Green Design

Sustainable manufacturing machine design offers a win-win scenario for businesses. By focusing on resource conservation and energy efficiency, manufacturers can significantly reduce their environmental footprint. This translates into a positive impact on the planet, aligning them with global sustainability goals. Additionally, sustainable design principles can lead to cost savings through minimized waste generation and lower energy consumption.

Beyond environmental and economic benefits, sustainable machine design can also enhance a company’s reputation. Customers today are increasingly conscious of eco-friendly practices, and a commitment to sustainability can be a major selling point. Furthermore, adhering to evolving environmental regulations becomes easier when sustainability is embedded into the design process from the very beginning.

Implementing Sustainable Design Principles

So, how can manufacturers translate these principles into action? A crucial step is integrating a life cycle assessment into the design process. This involves evaluating the environmental impact of the machine throughout its entire lifespan, from raw material extraction to disposal. This holistic approach allows engineers to make informed decisions about materials, manufacturing processes, and even end-of-life options.

Technology also plays a vital role in sustainable design. Advanced software tools like computer-aided design (CAD) can help engineers optimize both functionality and aesthetics, minimizing material usage and ensuring efficient operation. Additionally, simplifying design complexity can further reduce the environmental impact. Removing unnecessary components not only streamlines assembly but also minimizes energy loss during operation.

Material selection is another critical aspect of sustainable design. Opting for materials with lower embodied energy (the energy required to extract, process, and transport them) and those that can be easily recycled or reused can significantly reduce the environmental burden. For instance, utilizing high-efficiency, NEMA gearboxes, can not only improve overall system efficiency but also extend the lifespan of the equipment, reducing the need for premature replacements.

Safety plays a vital role not only for workers but also for the environment. Conducting thorough safety audits throughout the design process ensures the equipment operates safely and efficiently, minimizing the risk of accidents that could lead to environmental damage. Furthermore, integrating smart technologies like real-time energy monitoring and predictive maintenance systems empowers manufacturers to identify and address potential issues before they escalate into bigger problems.

Curious about the specific ways sustainable design can improve a machine’s environmental impact? The following infographic dives deeper into the benefits of sustainable manufacturing machine design, showcasing how each principle contributes to a greener future for the industry. By adopting these sustainable design principles, manufacturers can create machines that are not only efficient and productive but also environmentally responsible.

Back to top ↑

A robust MOS is vital for mining and metal companies to navigate the challenges of today’s market.

Management operating systems (MOS) are making significant impacts to performance goals and outcomes for mining and metals companies by providing a structured and systematic approach to managing the business across the value chain. Companies have a strong need for robust MOS in today’s market to ensure safety and compliance, improve efficiency, and achieve sustainable growth, given the safety of workers is a top priority across the mining industry;  the global demand for minerals and resources is rising, leading to increased competition; mining operations are inherently complex; the industry is facing significant cost pressures from fluctuating commodity prices and rising operational costs; and the adoption of new technologies requires an integrated approach to managing operations.

Performance is improved by providing a structured framework for planning, monitoring, and controlling operations. MOS can help through:

1. Safety and Compliance – ensuring that safety protocols and regulatory compliance are integrated into daily operations, while minimizing the risk of accidents and legal issues, promoting a safer working environment.
2. Enhanced Planning and Scheduling – creating detailed and realistic operational plans and schedules, ensuring that resources are allocated efficiently and that production targets are met without unnecessary delays. Potential bottlenecks can be identified and addressed during the planning process – “Planned work is safer and more productive than unplanned work.”
3. Real-Time Monitoring and Control – tracking operations in real time, allowing for quick in identification and in-shift resolution of issues, while reducing downtime and safeguarding that operations run smoothly.
4. Improved Communication and Coordination – standardizing processes and providing clear protocols, MOS enhances communication and coordination among different departments and teams, leading to more cohesive and efficient operations.
5. Data-Driven Decision Making – providing and analyzing comprehensive data on various aspects of the operations to identify trends, inefficiencies, and opportunities for improvement and leading to more informed decision-making.
6. Cost Control and Efficiency – optimizing resource use and reducing waste, while aiding in cost control and improving operational efficiency.

Supporting mining and metal companies to stay competitive and adapt to changing market conditions, MOS fosters a culture of continuous improvement by regularly reviewing processes, identifying areas for improvement, and implementing changes.

MOS in mining and metal operations are significantly enhanced by today’s technological advancements. By leveraging these advancements, MOS becomes more robust, responsive, and efficient. This not only enhances operational performance but also ensures better safety, sustainability, and profitability.

USC partners with your organization and coaches your people to significantly impact performance outcomes and accelerate Operational Excellence

USC brings a tailored, structured, and disciplined methodology, along with a range of tools and techniques we apply collaboratively with client’s personnel. Whatever your challenge, we are the people who work with our clients to find full potential and unlock the hidden value.

USC identifies waste, redundancies, and ineffective processes, and then rapidly recover the prioritized opportunities, and convert them to improvements in performance and operating profit. Our consultants achieve this by improving the skills sets of all levels of the client’s management and employees.

Our people embed with client internal teams to develop, enhance, prototype, validate and implement management operating system (MOS) element improvements to drive, sustain and perpetuate change in how the business budgets, plans, schedules, assigns work, executes, follow-up, reports, analyzes and improves. In short, USC implements measurable, sustainable changes that drive operational and financial improvements.

Our Management Operating System (MOS) Essentials Framework is designed to be pragmatic rather than conceptual – thereby leading to accurate, practical decisions about your operations and outcome aspirations. The key, that many miss, is the linkage process execution with management behaviors. MOS is about “managing differently” using visibly deployed management and supervisory behaviors. Consistent execution of the right behaviors at the right time creates certainty in the workplace, driving performance improvement and sustainable new ways of working.

Client performance goals and outcomes are realized through:

• Integrated safety protocols and compliance requirements into daily operations., leading to a safer work environment and fewer accidents.
• Reduced operational costs, including minimized waste, optimized equipment usage, and reduced energy consumption.
• Optimized workflows and resource allocation, leading to increased efficiency and higher production rates.
• Effective maintenance planning and real-time equipment monitoring, MOS reduces unexpected breakdowns and downtime.
• Alignment of daily operations with strategic objectives, ensuring that all activities contribute to the company’s long-term goals.
• A culture of transparency by providing clear performance metrics and regular reporting while driving better performance and tracking progress towards goals.

USC Helps You Tackle Key Challenges

• Optimize mine planning and scheduling across all planning horizons – delivering detailed and accurate plans
• Identify potential roadblocks proactively during mine planning and solve complexity during the planning process
• Ensure the right resources are at the right place to minimize lost time – enabling safe and disciplined execution
• Control quality of work at the point of execution by identifying off specification and enabling in-shift correction
• Evaluate performance and identify opportunities for improvement, enabling continuous improvement mindset

Do you want to understand how a MOS can integrate you mine and operational planning, while helping you to safely increase performance site wide?

Want to find out more about how USC can help you uncover the hidden value loitering in your operations?

For more information, let’s talk it through with a no obligation meeting with one of our executive team members. Email info@usccg.com to arrange a call.

Back to top ↑

Remember when artificial intelligence (AI) was a glimmer on the horizon? And then ChatGPT stormed onto the scene and people were convinced every job out there was soon going to be replaced by a bot? Now it turns out, not so much.

As awesome (and we don’t use that word lightly) as AI is, it’s only as good as the data it has to work with. At USC Consulting Group, we’re finding this is especially true when we’re using AI for predictive analytics. AI doesn’t like variation, and there can be a lot of that in manufacturing processes.

Here’s a look into this issue and how to handle it.

A short primer into AI and predictive analytics

AI is a broad term describing computer systems that perform intelligent tasks, like reasoning, learning, problem solving, and more. Not so obvious is predictive analytics, which is the ability to forecast future outcomes using AI based on data. You’re already familiar with it, to a certain degree. If you’ve ever had a recommendation from Netflix based on what you’ve watched in the past, that’s it. In a nutshell.

Netflix’s use of predictive analytics created a seismic shift in consumer expectations. This technology also has the potential to transform operating procedures and processes for many industries.

It’s extremely powerful when dealing with processes in which multiple predictors are influencing outcomes. It has the ability to tell us which path to take in order to achieve a desired outcome, even when process patterns and trends are changing.

It means greater precision and accuracy, speed and increased efficiency, the holy grails for any manufacturer.

But there is a fly in this cyber ointment.

Variation.

AI doesn’t like it and – low and behold – that means humans are necessary in this process in order for predictive analytics to achieve its potential.

What is variation?

When we’re talking about manufacturing processes, what exactly does variation mean?

In manufacturing, variation is the difference between an actual measure of a product characteristic and its target value. Excessive variation often leads to product discard or rework.

When you’re dealing with high process variation and instability, it degrades efficiency, consistency and ultimately, profits. A key manufacturing performance objective is the establishment of stable and predictable processes that limits variation – minimum variation around target values.

A main focus for USC Consulting Group is to identify the root causes of variation and address them. Generally, it boils down to people, components and materials.

Some examples to causes of variation include:

• Poor product design
• Poorly designed processes
• Unfit operations
• Unsuitable machines/equipment
• Untrained operators
• Variability from incoming vendor material
• Lack of adequate supervision skills
• Changing or inadequate environmental conditions
• Inadequate maintenance of equipment
• Inadequate or changing environmental conditions

It can be one of these factors, several, or something else. But whatever it is, it’s impeding our ability – and the bot’s – to predict outcomes.

Minimizing variation with our Customized Quality System (CQS)

Every situation is different. The cause of variation on one manufacturing line isn’t going to be the same on another. USCCG assesses and evaluates client processes, then applies a customized approach using a series of tools, techniques and methods that is most applicable in addressing the causes of variability. This customized approach enables USCCG to address variability in an efficient manner. We call it our Customized Quality System (CQS).

We review processes from “the cradle to the grave” and identify the highest-impact operations, then drill down to the tasks and steps within those operations until we uncover the culprits.

Although every situation is different, the general roadmap includes:

• Carefully defining the problem
• Selecting the right team
• Objectively identifying high-impact operations
• Drilling down into the tasks within those operations
• Brainstorming possible causes on those high-impact tasks
• Recommending and implementing deeply focused corrective actions
• Controls so it doesn’t happen again

Removing variability through our CQS not only has an immediate impact on improved product conformance but also paves the way for AI to do its job in predictive analytics, i.e., we want predictions with minimum variability.

It’s just one way USC Consulting Group is using the human touch to make sure AI is up to the job.

Read more about this in our free eBook, “AI and Machine Learning: Predicting the Future Through Analytics.”

Back to top ↑

The manufacturing industry keeps society ticking, but it consists of people. As technology advances, using it to improve worker safety reigns paramount, protecting the individuals who move the machines that create the products society uses daily. Keeping abreast of the latest developments to improve industrial health and safety helps owners and managers improve working conditions and processes.

Such improvements span every aspect of the industrial process, from producing the products to warehousing them and delivering them to customers. Responsible parties can draw inspiration from the innovations below to improve industrial hygiene and safety for a healthier and happier workforce.

Warehousing Procedures

Warehouses combine multiple workers and machines in a single small space, increasing the risk of accidents. Injuries can result from equipment misuse, failure to follow safety procedures or overuse stemming from repetitive motions. For example, approximately half of all workers at certain warehouses experience an injury within their first three years. Facilities have begun to implement the following innovations to decrease accident risk.

1. Warehouse Management Systems

These advanced computer programs boost efficiency by optimizing travel routes and times to streamline picking and putting away procedures. They can prevent “traffic jams” in aisles and decrease fall risk by keeping moving equipment like forklifts out of areas where workers are using ladders or scaffolding.

2. Robotics

Robots reduce repetitive motion injuries by taking some of the heavy lifting off human hands. Additionally, they can reduce fall risk by retrieving items on high shelves. Such technology also empowers warehouse managers to make better use of vertical space instead of increasing their facility’s footprint.

3. Appropriate Safety Gear

Relying on workers to supply PPE can result in the most vulnerable going without or investing in inferior protection to meet company requirements. Providing gloves, facial protection, hearing protection, steel-toed boots and reflective vests protects workers against sudden traumatic injuries while reducing some of the wear and tear of daily work on their physical selves.

Lockout/Tagout

Lockout/tagout procedures protect against electrocution and other traumatic events, such as crushing injuries when a piece of equipment goes down and multiple workers must coordinate their efforts to correct the problem. OSHA guidelines cover proper measures for controlling energy from electrical, mechanical, hydraulic, pneumatic, chemical and thermal sources. Compliance with these standards saves an estimated 120 lives yearly.

Here, too, technological improvements enhance worker safety. For example, video surveillance ensures workers apply the appropriate lockout devices to equipment before service work begins. Sensors can alert workers to energy remaining trapped in the system or sound the alarm if a stray body part enters the restricted area. Improved equipment testing ensures refurbished equipment meets lockout regulation standards before operators put it to use.

Heavy Equipment

Improvements in heavy equipment also increase safety in industrial environments. Electric forklifts produce fewer emissions than previous models, sparing workers’ lungs, and their narrower bodies and smaller turning radius prevent accidental collisions in crowded warehouses. They’re also quieter, reducing noise pollution. Approximately 18% of industrial workers have a hearing impairment, which lowers their life quality and may increase dementia risk.

Forklifts aren’t the only heavy equipment going electric. Many facilities have begun to outfit their organization with full electric fleets, and even bulldozers are joining this technical revolution. Electric vehicles typically have less complicated engines, leading to fewer malfunctions and opportunities for injuries to occur as crews scramble to find workarounds.

Fall Prevention

Falls from heights are the number one cause of workplace death in the UK and lag behind only transportation and workplace violence in the United States. The term “fall from height” is somewhat misleading, as many of the fatalities involved falls from lower levels, not towering skyscraper beams.

Improved safety technology and procedures work in tandem to prevent falls. For example, requiring harnesses for work involving ladders and scaffolding can reduce the risk of injury if the standing structure falls or an accidental bump sends it tumbling. Providing additional training is another safeguard, as advances in computer technology allow workers to remediate as needed instead of waiting for a single group training to refresh their knowledge.

Worker State of Mind

Improvements in technology won’t go as far as they can in increasing industrial hygiene and safety without the buy-in of the workers running operations. One of the simplest yet most effective methods of bringing up safety scores is to simply slow down. While this mindset goes against the obsession with productivity and metrics typical of many facilities, it’s a rebalancing of modern reality with human ability.

Consider an experiment on seminary students asked to give a speech on “The Good Samaritan” parable. Researchers told one group their participants were already waiting, creating a hurry. The second group was told they had just enough time, and the third was told they had more than enough. Even given the topic of the speech, only 10% of the hurried participants stopped to render aid to someone in need as they crossed campus, while 63% of the unhurried students paused.

Technology has increased overall productivity but has also added responsibilities for workers without a corresponding drop in working hours or adequate time to absorb new information and procedures. Exhaustion and burnout can lead to mistakes that cause injuries and cost lives.

Recent legislation to shorten the average workweek, if passed, could reduce the burnout many feel, improving workplace safety. In the meantime, site leaders can emphasize quality over quantity and stress safety over metrics in determining raises and bonuses to decrease the temptation to cut corners to make numbers.

Improving Industrial Hygiene and Safety

Workplace injuries cost countless lives and disrupt operations. Improving industrial hygiene and safety demonstrates a commitment to a strong, healthy and thriving workforce.

Site owners and supervisors should periodically review the latest updates to improve their operations. Keeping workers safe decreases liability, enhances workflow and results in a happier, more productive environment.

* This article is written by Jack Shaw. Jack is a seasoned automotive industry writer with over six years of experience. As the senior writer for Modded, he combines his passion for vehicles, manufacturing and technology with his expertise to deliver engaging content that resonates with enthusiasts worldwide.

Back to top ↑

Global supply chains are intricate networks that span multiple countries and continents, involving a multitude of processes, from procurement to distribution. The complexity is further compounded by varying local standards and regulations, making standardization a critical need.

The United Nations Standard Products and Services Code (UNSPSC) provides a universal classification framework that is essential for streamlining these complex processes and facilitating seamless international operations.

Benefits of UNSPSC

UNSPSC serves as a global language for businesses, ensuring that products and services are categorized consistently regardless of where they are produced or consumed. This standardization is vital for global trade, as it simplifies communications between suppliers and buyers, enhances spend analysis and reporting capabilities, and improves procurement efficiency.

By adopting UNSPSC, companies can ensure more accurate demand forecasting and inventory management, which are crucial for maintaining the flow of goods and services across global markets.

AICA’s Automated Approach to UNSPSC

Data management and cleansing specialist AICA offers a SaaS platform that leverages advanced AI and ML technologies to automate the UNSPSC classification process. This automation is driven by AI models trained on extensive datasets, significantly increasing accuracy and reducing errors commonly seen in less sophisticated systems.

The process of manually classifying products into UNSPSC codes is a task that traditionally requires substantial time investment. For instance, cataloguing a single product into the UNSPSC framework manually takes approximately 10 minutes. Classifying 10,000 products would, therefore, require about 69 days. Thus, manually classifying products consumes a significant amount of time, representing a substantial opportunity cost.

However, AICA’s platform automates this process and assigns the classified items with an accuracy score. Items that receive a quality score lower than 93% are flagged for review by our subject matter experts.

Here’s a breakdown of the time savings:

• Total manual classification time for 10,000 products: 69 days.
• Time required using AICA’s platform with automated and expert review: Only the items with a quality score below 93% are manually reviewed. This drastically cuts down the overall manual intervention and time needed compared to the traditional method.

Thus, by using AICA’s system, a task that would normally take over 69 days of continuous work can be reduced significantly to only a few.

This methodology not only speeds up the classification process but also ensures a high level of accuracy and reliability, allowing businesses to deploy resources more effectively and enhance overall productivity in the supply chain.

Universal Relevance

The relevance of UNSPSC and AICA’s technological solutions extends across various critical sectors, including Manufacturing, Mining, and Aerospace and Defense. These industries face unique challenges such as managing complex assemblies, complying with strict regulatory standards, and handling high-value inventories.

UNSPSC codes help standardize component classifications, making it easier to track and manage parts across global supply chains. For these sectors, the ability to accurately classify and analyze product data can lead to more strategic sourcing and better risk management.

Conclusion

For global enterprises aiming to improve their supply chain operations, adopting AICA’s UNSPSC-classifying technologies offers a transformative opportunity. By integrating our solutions, companies can benefit from enhanced data accuracy, improved operational efficiency, and a competitive edge in the global market.

*This article is written by USCCG’s strategic partner, AICA Data. AICA is a data cleansing and management specialist that optimizes your product and services data with AI to provide faster, more accurate, and cost-effective solutions. To find out more about AICA’s services – visit their website here.

Back to top ↑

Downtime – the dreaded halt in production that can cripple a manufacturing operation. It’s more than just an inconvenience; it’s a hidden cost that can eat away at your profits. A recent study revealed that nearly 82% of businesses have experienced unexpected downtime in the past three years, with the average incident lasting four hours and costing a staggering $2 million. The impact goes beyond just financial losses – downtime can disrupt customer deliveries, delay critical projects, and erode trust with clients.

The Potential Culprits

One major factor is neglecting preventive maintenance. Regular servicing not only keeps equipment functioning smoothly but also allows technicians to identify potential problems before they snowball into major breakdowns.

Another hidden source is outdated equipment. Obsolete machinery can be a drag on your entire production line. Imagine a slow, malfunctioning piece of equipment holding up the entire process. This can put undue stress on other machines, leading to premature wear and tear, and ultimately, more downtime. Upgrading to newer, more efficient models can significantly improve production flow and reduce the risk of breakdowns. Outdated software can also be a culprit. Running outdated software can lead to compatibility issues with newer systems and leave your facility vulnerable to security breaches.

Beyond equipment and software, a lack of proper training for your workforce can also contribute to downtime. If operators don’t fully understand how a machine works, they might misuse it, leading to errors and breakdowns. Investing in comprehensive training empowers your employees with the knowledge and skills they need to operate machinery safely and efficiently, minimizing the risk of operator-induced downtime.

Finally, the importance of data tracking cannot be overstated. Keeping detailed logs of equipment issues and production hiccups allows you to identify recurring problems and implement preventative measures. Think of it as a historical record that helps you anticipate and address potential bottlenecks before they derail your production schedule.

Finding the Right Solution for You

The good news is that there are steps you can take to combat downtime and keep your production lines humming. Conducting risk audits to identify potential problems, installing sensors to monitor equipment health (like a torque transducer that detects excessive force on a rotating shaft), and implementing a comprehensive preventive maintenance program are all crucial steps in the battle against downtime.

Investing in employee training and partnering with reliable third-party service providers can further strengthen your defenses. By adopting a proactive approach to maintenance and addressing the root causes of downtime, you can significantly reduce disruptions and ensure your manufacturing operation runs smoothly and efficiently.

Want to learn more about the specific costs associated with different downtime causes? The following infographic breaks down the financial impact of various downtime triggers, helping you identify areas for improvement and optimize your production process for maximum uptime.

Back to top ↑