Digital Manufacturing Maturity Assessment

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How do you manage unexpected changes or needs during production?

We do not have a formal process and handle changes informally as they arise.	Supervisors verbally communicate changes to the team when necessary.	Alerts are broadcast to the team on a digital bulletin board.	Operators receive real-time updates from an integrated digital production system.

How are you maintaining a log of scrap versus quality products?

You do not track scrap.	Operators jot down the scrap count on paper manually.	Operators log scrapped parts in your ERP or another system manually at shift end.	Operators input scrap and quality data using an in-house app.	Real-time tracking of scrap versus quality through fully automated sensors and reporting.

How do you onboard and train new employees?

New employees learn by shadowing a manager for a set period.	New hires receive a paper manual of instructions.	You combine shadowing with manual training sessions.	New employees use training videos and interactive modules.	You employ a comprehensive digital training platform with monitoring and feedback.

What steps do you have in place to ensure you are prepared for any customer audits?

Supervisors inspect operators' handwritten notes to trace issues.	You record issues on a computer daily for tracking.	Inventory and consumption data is tracked in real-time via mobile devices	Software automatically correlates data to identify problems using advanced analytics.	Inventory and cost data is attached to disruption events in real-time via mobile devices	Mobile/Cloud integration with ERP for consumption and reorder using barcodes and RFID devices

How do you manage inventory?

You manually update inventory on paper periodically.	Inventory data is keyed into a spreadsheet or database by hand.	You utilize barcode scanning for inventory management.	The system employs real-time, automated inventory tracking with RFID or IoT sensors.	Your system refreshes automatically as operators process production, triggering necessary material orders.

How do you schedule machine maintenance?

We perform maintenance only when a machine breaks down.	Maintenance is scheduled manually based on manufacturer recommendations.	We use a calendar system to schedule regular maintenance.	Digital reminders notify us about upcoming maintenance.	AI predicts and schedules maintenance based on current machine performance.

How do you integrate customer feedback into production processes?

We rarely collect and/or use customer feedback to improve processes.	You collect feedback manually and sometimes review it in meetings.	We have a system in place for recording customer feedback, which is reviewed quarterly.	Digital tracking of customer feedback informs production planning.	Agile production systems integrate customer feedback in real time to encourage ongoing improvement.

How are work orders generated and managed on the shop floor?

Work orders are written by hand and passed to the production team.	Work orders are printed out and manually distributed to the appropriate teams.	We use digital documents to manage work orders but print them out for the floor.	Work orders are generated and distributed via an in-house computerized system.	An end-to-end ERP system automatically generates and tracks work orders in real-time.

How are health and safety incidents recorded and acted on?

We do not have a formal system for recording such incidents.	Incidents are noted in a logbook and reviewed occasionally.	Incidents are recorded manually and entered into a database for reporting.	A digital form is used to record incidents with email alerts to relevant personnel.	An integrated safety management system automatically flags incidents, alerts management, and triggers preventative measures.

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Manufacturing Maturity Quiz