There are numerous system for your business, and it makes it hard to choose which one is the perfect and needed by your company. Lots of company has lost million dollar by choosing the wrong systems, that’s why you need to stay informed about what causes new system to fail, and this will prevent your company from failure with your own system. In this article we are going to show you the most common reasons why new manufacturing systems fail after implementation. 


  1. A faulty inventory item numbering scheme It is pretty common for a company to have more than one supplier, and your system need to have this option, multiple supplier capabilities, if not then the worst case scenario is your company will have out of stock item but the truth is there are items from other supplier. Lastly, it is a good idea for the system to have a cross-reference between your internal part number and each supplier’s part number
  2. Insufficient control of content for bills of material. Try to restrict unqualified people from using certain critical functions of the software by increasing the security system. Sometimes in practice the bills of material has the right components in theory, but then people on the shop floor start to personalize as they assemble.
  3. Inaccurate inventory on hand. The advantages of having integrated system is to reduce redundancy in your company system. But it has a drawbacks that if your inventory is miscounted from the start, the error will repeat itself throughout your system. So, you have to check inventory manually and shut down the system to solve the error. It is a good idea to have a function of correcting stock counts without having to shut down the system.
  4. Lack of agreement between engineering and manufacturing. Having an agreement between engineering and manufacturing is essential to set the same goals how to get to the goals. It is important to have buy-in from these two departments, and you can consult with your consultant to develop a thorough implementation plan, so that each of the departments are aware of this.
  5. Unrealistic expectations of what the system will be able to accomplish. Spending money for your investment wisely is a good way to buy what you need. For example, you do not want to buy a Ferrari to go on off-road, or buy a Hummer to use it in a track race. So, buying the functionality that your company need from a system, but not the most expensive system but yet you do not use the functionality.
  6. Failure to determine the company’s needs in accounting, manufacturing, engineering and data collection. Try to get a report of what needed and goals from each departments, before you implement the system. This mandatory step is not to be skip, as you can go back to this step but it will be too late. So, consult and ask to be train by your consultant before you make any move.

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