A new software solutions and technology upgrades filter into the manufacturing industry, system developers tend to focus on back-office personnel and machines, said Bob Lazlo, director of sales and marketing for Brookfield-based Guardian Business Solutions Inc. (GBSI).
Systems including Six Sigma applications, radio frequency identification (RFID) and manufacturing execution systems (MES) improve machine efficiency and cut operating costs by eliminating the probability of human error.
However, system developers have overlooked those working on the shop floor and underestimated their need for efficiency. Workers need to keep track of orders, receive changes in materials and be able to contact a back-office worker, a supervisor or an engineer without wasting time.
In an environment where communication is key, a software solution that provides the transfer of updated information is equally important.
Bridget Lazlo, president and partner, and James "Miff" Keepers, executive vice president and partner of GBSI, launched Shoptalk, software geared toward the shop floor, in 2001 to aid workers and improve productivity.
"MES can be expensive, difficult to integrate and focuses on integrating areas on the floor more than integrating the workers," Bob Lazlo said. "Shoptalk is a streamlined version of an MES that is easier to integrate, affordable for small and mid-sized companies and is geared toward the workers on the shop floor."
With Shoptalk, workers can access the company’s database through buttons on a touch screen. Shoptalk connects with files linked from company departments and pulls information for shop floor workers from any format, from a Microsoft Word or Excel file to computer aided drafting (CAD) files and MPEG files, which hold moving pictures.
When a worker needs to look at an engineer’s diagram, check for quality control, packing or a paint color, it is all available through Shoptalk.
Typically, in facilities that have not implemented Shoptalk, administrators have to collect pieces of information, laminate each page to prevent dirt and liquids from ruining them and put them together in a manual that stays on the shop floor as a resource, Bridget said.
GBSI developed Shoptalk after researching the major benefits that MES could bring to large, mid-sized and small companies, Bob said. Shoptalk is a software solution that integrates with any program the manufacturer uses, including computer aided drafting (CAD) and administrative programs.
Workers, computer proficient or not, can use the system to pull needed information, including design notes, blueprints, warnings, changes and shipments, Bridget Lazlo said.
"Shoptalk was designed to be used quickly, which is a very important principle. We have seen what happens when things get too complicated," Bob said. "If we are going to compete with companies without labor laws and environmental standards overseas, we have to be more efficient. Workers need to get on Shoptalk, get the information and get off."
Shoptalk has three purposes, Bob said. It serves as an information station, a data collection station and a communication station.
The system consists of Shoptalk software, monitors with touch screens and accessories, including microphones and carts for mobility. The program ranges in price from $1,800 to $2,500 per station. Each station includes software, hardware and optional accessories.
The touch screen can be mounted on a cart with a shelf to place the screen and a shelf for the battery. A Shoptalk system can be unplugged and moved to accommodate a worker who needs to go to his or her station.
Shoptalk Mobile is another product from GBSI that puts the entire Shoptalk system on a vest for mobile workers who are picking, scanning or fixing machines and need product information at their fingertips. Shoptalk Mobile ranges in price from $3,500 to $4,800 per vest and includes software and optional accessories.
The touch screen makes the system easy to use while wearing gloves and allows Shoptalk to be used effectively without the nuisance of a keyboard. GBSI uses voice technology to confirm a command, allowing the user to speak with other employees or to announce a change in schedule or a shortage of materials, Bridget said.
"It was very important that the design was visual in that workers had to be able to understand without significant training," Bridget said. "On the shop floor, there can be language barriers or workers with reading disabilities. A lot of workers are not computer people."
Shoptalk was intentionally created to be easy to read and easy to use. The program can talk a user through a process, if needed. Users can choose the text-to-speech option, where the computer repeats what the user writes.
"Whatever the users write can be activated," Bob said. "By reading, seeing and hearing the protocol, workers can comprehend faster, and their retention is longer."
The administrative tool only requires the administrator to link a file with the Shoptalk program. No maintenance is required, as long as there is logic to where the administrator stores files. An administrator can be trained to use Shoptalk in 15 minutes, Bridget said.
"We had to get away from the conventional Microsoft screen that is designed for a mouse or a keyboard," Bob said. "A person’s eye is intuitively drawn to the prompts, and the colors highlight the next step or alert a user when new information is available."
Shoptalk easily integrates with structured query language (SQL), the programming language that sends queries to databases, and open database connectivity (ODBC), a method of sharing data between databases and other programs.
GBSI is now integrating Shoptalk with a company’s enterprise resource planning (ERP) software, which correlates information needed for customer orders, and with labor systems, where workers can clock in and out through Shoptalk.
Shoptalk eliminates the need for labor intensive manual updates and ensures proficiency on the shop floor, the Lazlos said.
When workers use the touch screen to retrieve information about a product, Shoptalk connects directly with a file on the company’s database through a linking system. The file a worker retrieves is the same file that an engineer saved on his or her computer, which makes Shoptalk effortless to update and eliminates mistakes caused by a miscommunication.
Bridget has more than 25 years of experience in the manufacturing industry and founded GBSI with Keepers after working as a software developer and implementer for manufacturing and distribution companies.
"When workers are as productive as possible, there are fewer chances for errors," Bridget said.
Elizabeth Geldermann is a reporter for Small Business Times. Send technology news to her at elizabeth.geldermann@biztimes.com or by calling her at (414) 277-8181, ext. 121. Technology news can also be sent to: Elizabeth Geldermann, Small Business Times, 1123 N. Water St., Milwaukee, WI 53202.
Great Lakes Media Technology
Great Lakes Media Technology has added manufacturing equipment to its Mequon plant to produce the Hybrid Super Audio compact disc, known as the Hybrid SACD. The new disc, which was designed by Sony and Philips, provides the "warmth" of the analog recording process in a full surround sound presentation. Many record labels are re-mastering their back catalogs and re-releasing SACD discs to give listeners the experience of hearing the music in the new and improved format. Great Lakes Media believes the new format will become standard over time. Great Lakes Media is a licensed manufacturer of Philips optical media.
RedPrairie Corp.
RedPrairie Corp. of Waukesha announced that its radio frequency identification (RFID) supply chain solutions now can provide food and beverage manufacturers with tools necessary to support compliance with U.S. Food and Drug Administration (FDA) regulations related to the Bioterrorism Act of 2002. Final mandates issued by the FDA on Dec. 6, 2004 require food and beverage manufacturers to be able to track food products throughout the entire food and animal supply chain by December 2006. RedPrairie company leader John Jazwiec said, "RedPrairie recognizes that government regulation increasingly impacts the way our customers do business. In response to recent mandates, RedPrairie enables our leading customers to track FDA required information." Redprairie also announced that The Container Store, the nation’s leading retailer of storage and organization products, has selected RedPrairie’s labor management software program to help the company manage its growth.
SBC Communications
SBC Communications, Milwaukee, formed a joint venture with 2Wire Inc., San Jose, Calif., to deliver a home entertainment service that integrates satellite TV programming, digital video recording, video on demand and Internet content including photos and music via a new set-top box. The system works with the SBC Yahoo! user interface. The joint venture is part of a two-pronged SBC video strategy to extend home entertainment video services to customers through either high-speed fiber or DSL. The service will include a satellite TV receiver, digital video recorder (DVR) and storage for digital photos and music. The 2Wire MediaPortal technology will provide integrated SBC Yahoo! DSL, SBC | DISH Network satellite TV and home-networking services. Customers will be able to access photos and music and schedule their DVR remotely from any Web-connected computer through SBC Yahoo! and future enhancements will allow access through Cingular Wireless phones. The offering will be available in mid-2005 to customers who have both
SBC | DISH and SBC Yahoo! DSL services.
Backlot Imaging, Inc.
Backlot Imaging, Inc., Milwaukee, provided visual effects for "Elektra," the action film from 20th Century Fox starring Jennifer Garner. Backlot crafted special effects sequences in the style of "Crouching Tiger, Hidden Dragon" to bring to life Elektra’s martial arts battle scenes. Backlot also used effects software and hardware for wire and rig removal, erased traces of equipment for flying stunts and performed digital garment repair. Elektra is the sequel to "Daredevil" and follows the assassin Elektra on her assignments.
Verizon Wireless
Verizon Wireless, Bedminster, N.J., launched its Evolution-Data Optimized (EV-DO) third generation (3G) wide-area network in the Milwaukee metropolitan area. The EV-DO 3G network enables BroadbandAccess and will enable VCAST, a 3G wireless multimedia service for consumers. Verizon customers will be able to use new handsets to access VCAST’s video on-demand service, viewing current news, weather, sports and entertainment programming. Customers will also be able to download and play three-dimensional games on new handsets and watch music videos and short programs specifically designed for mobile phones and other video applications on the handsets. For $15 monthly access in addition to a regular Verizon calling plan, VCAST customers in Milwaukee can have unlimited access to daily updated videos and unlimited browsing of Mobile Web 2.0 news and information service.
AdCom Technologies
AdCom Technologies, Sheboygan, is offering consultation, installation and service for voice-over Internet protocol (VoIP) systems. Businesses choose the system that best meets their immediate needs for size, features and price point. After AdCom installs a VoIP system and trains key employees, the system is managed internally. AdCom recently merged with Mainline Information Technologies, Sheboygan, to provide VoIP systems; traditional phone systems; computer network security audits; server consolidation, analysis and implementation; software and hardware installation and upgrades; capacity performance planning and general IT supplemental staff and training.
February 4, 2005, Small Business Times, Milwaukee, WI
