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72 SMT Magazine • August 2014 available for operation on any line configura- tion in the factory as needed. Live production planning software is actually the first stage in the production preparation now in best prac- tice cases, putting together the combinations of products, optimizing feeder setups for zero-loss changeovers, and optimizing performance. Pro- cess preparation software delivers any needed programming for any line configuration, which creates product portabil- ity, the ability to produce any product on any line configu- ration at any time, without significant engineering cost or down-time. The execution of rapid planning decisions based on flexible customer de- mand also mandates Lean ma- terial delivery to machines to avoid needless physical shop- floor material WIP. Not only does this avoid the need to re- recount and move materials whenever a planning change is made, there is a significant cost saving of excess material investment. Taking total control of ma- terials across the shop-floor and warehouses provides very high accuracy of material in- ventory, which is critical for low-risk planning change ex- ecution and for good communi- cation back to raw material suppliers. The Lean manufacturing engine, driven by live planning, brings the necessary enhancement to ERP to create a new manufacturing paradigm necessary to meet the demands of the market— performance and flexibility together, designed from the ground up. These innovations are, of course, not limited to new factories. Existing manufacturing operations can also implement these practices to move to the next level of competitiveness. a More Favorable Environment for Reshoring In terms of manufacturing costs then, the playing field has leveled off somewhat in recent years, most significantly for distribution and demand pattern satisfaction, also for labor and materials costs because of increased automation in machinery, and last but not least, enhance- ment to manufacturing engineering, planning, and supply chain. The arguments for offshore manufacturing are certainly now much weaker than they once were, so now let's explore the other positives for reshoring. The environment is often put forward as a key positive for reshoring. The final shipping cost to the environment in terms of jet fuel or marine die- sel comes easily to mind for most people; however, trans- portation throughout the whole product manufacturing cycle is a much more complex subject. Other factors, howev- er, can be of stronger signifi- cance in a business context. Looking at the more se- rious side of the electronics manufacturing market, we see high reliability and safety crit- ical products are more likely to have remained on-shore. The reasons include quality, control, and responsibility. The effect of poor quality or unreliable products is no lon- ger exclusive to military, aero- space, medical, and automotive. With consumers now making product reviews posted on Internet shopping sites and the popularity of social media, a single defect found in a popular product in the market can cause significant business opportunity loss and can be a threat to brand image. The media is also today keen to expose sensational stories of how products can fail. Quality is Critical Quality is more critical today than ever be- fore, for competing in today's market. Quality in manufacturing comes from control, trace- ability, and assurance that work is performed correctly every single time, as well as insurance to know that if ever anything does go wrong, Looking at the more serious side of the electronics manufacturing market, we see high reliability and safety critical products are more likely to have remained on-shore. The reasons include quality, control, and responsibility. The effect of poor quality or unreliable products is no longer exclusive to military, aerospace, medical, and automotive. " " eSSenTiAl pioneer'S SurViVAl guiDe REshORINg MaDE sIMPLE continues