BLACKHAWK SYSTEMS, INC.
SFE Benefit Statement     

Blackhawk’s vision is that within the repetitive world the only way to continually improve the manufacturing method is to be able to measure where you are. When this measuring can be performed in an accurate and real-time fashion, the plant can both proactively and reactively move towards reduced cost, improved part production, and improved part quality, at the same time accurately fulfilling the customer requirements in a timely manner.

The Blackhawk SFE Solution brings the following to the repetitive manufacturing floor.

• Reduced Costs
  
  Reduced scrap
  To deal with the scrap levels, you first need to know where the levels are. Blackhawk SFE enables the immediate identification of where your scrap levels are, and the reasons that they are occurring.
  
  Reduced data entry costs
  The paperless recording of production/scrap/reject/rework prevents the problems caused by using paper-recording methods. Everything from paper loss to the miss-entry of what has been recorded on the paper causes the ERP/MRP system to be inaccurate. Blackhawk SFE eliminates the cost of keying production data as well as the problems associated with it.
  
  Reduced inventory levels
  Most automotive part suppliers carry more inventory than they need to for insurance sake. If your MRP/ERP numbers were more accurate, your vendor releases would be more accurate, and you could confidently reduce your inventory.
  
  Reduced expediting charges
  Most expediting charges are not due to customers changing their requirements. If your MRP/ERP numbers were more accurate, your expediting charges would drop.
  

• Increased Quality
  
  Four levels of online documentation (QS9000 – Work instructions etc.)
  There are four levels of on-line documentation available to the line workers. Everything from quality alerts to QS9000 documentation is available. All documentation may include pictures, audio and video.

Defect Identification
The ability to identify the re-occurring defects enables you to identify where your biggest scrap issues are. And by labeling (where possible) these scraped items, you can eliminate these parts from being used later in your manufacturing effort.

FIFO – Inventory Handling
First in – First out inventory handling encourages the consumption of the oldest stock. It also quickly identifies when stock is being miss-handled, miss-placed or stolen.

Item Traceability (example: air bags)
This is the ability to record the serial number of a component part that is being used to build another component part or finished good. Done when the customer requires it.

Lot Traceability (example: the bolts that are used in the air bag)
This is the ability to record the lot (serial number) of the component part’s container that is being used to build another component part or finished good. This is becoming a customer requirement.

Real-Time Trend Analysis of Production/Scrap/Reject/Rework
You cannot overstate the importance of real-time production recording. Real-time trend analysis allows you to pro-actively change your manufacturing schedule to meet customer requirements. Real-time trend analysis enables you to identify production issues that are immediately costing you money.

Extremely Detailed Product/Scrap/Reject/Rework Reporting
Each area within production reporting has well detailed reports. First run production, scrap and reject rates, perato reports, machine efficiency, downtime / uptime are just a few that are available. Most reports have drill down capabilities that allow you to review the extreme detail that supports the reported information.

Quality Hold Management for Internally Produced Goods
Within every manufacturing effort, there are quality issues from one work cell to the next. By treating every work cell as a customer to the previous cell and a supplier to the following cell, internal production quality issues are cleanly and immediately identified. Parts that are internally rejected are put in quality hold and must be verified before they re-enter the production stream.

Enables Accurate Part Recovery by Using the Correct Bill of Materials
Part recovery from scrap product can only be of parts that are identified as those that can be recovered and that are on that part’s bill of material.

Enables Accurate Rework by Using the Correct Bill of Materials
Part replacement when reworking can only be of parts that are identified as those that can be replaced and that are on that part’s bill of material.

• Increased Visibilty
  
  Real-Time Production/Scrap/Reject/Rework Recording
  Real-time recording allows you to quickly identify trends and make any required adjustments to your production schedule. Real-time recording enables proactive efforts to meet your shipping schedule.  
  
  Identifies Individuals and/or Teams who Participated in the Production
  The identification of the team members who worked on a specific part increases quality. This identification also enables you to see who in your production team needs additional training. 
  
  Eliminate Non-Good Parts from the Production Cycle
  By labeling rejects, rework and scrap, parts that are not up to quality specifications are kept out of the manufacturing and shipment cycle.
  

• Improved Customer Service
  
  Greatly Decreasing Shipping Scheduling Issues
  Many shipping scheduling issues arise from not knowing what was produced at any given moment. Unforeseen scrap or reject rates cause chaos in the shipping schedule. Real-time production recording is the first step in solving shipping scheduling issues.
  
  Greatly Improves Labeling Accuracy
  Line-side labeling of the part when the part is produced greatly improves product-labeling quality. Scanning these part labels into containers or racks greatly decreases the occurrence of the wrong parts getting into the wrong container.
  
  Greatly Improves Shipping Accuracy
  Scanning parts into the shipping containers and then scanning these containers into the truck greatly increases the opportunity to ship what the customer requires.
  

• Improved Supplier Responsiveness
  
  Quality Hold Management for Purchased Product
  Suppliers have the same difficulties that you have in supplying properly labeled, quality product. Within the system, you have the ability to identify supplier quality issues, and keep the product from being used in your manufacturing process.
  
  In Stream Quantity Verification of Purchased Product
  Due to the complexity of repetitive manufacturing it is often difficult to verify the quantity within purchased goods? Cloth, paint, and resin are just a few of the purchased goods whose quantities are often suspected but are very difficult to verify. Because of the real-time reporting and the integral lot trace built with the system, you can identify supplier short/over shipments.

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Blackhawk Systems Inc.
877-575-2637
info@.blackhawksystems.com