Manufacturers running on AS400 (IBM i) often experience unexplained slowdowns, production inefficiencies, and data synchronization issues – even when their systems seem to be running fine. These hidden bottlenecks can erode productivity, inflate costs, and create compliance risks if left unchecked.
This is where expert AS400 automation developers come in. Unlike generic IT teams, these specialists understand the deep-rooted inefficiencies in legacy systems and can implement automation solutions that unlock maximum efficiency.
The Hidden Bottlenecks in AS400 Manufacturing Systems
1. Inefficient Batch Job Processing Slows Down Production
Many manufacturers unknowingly run batch jobs inefficiently, causing slowdowns in:
- Material requisition and order fulfillment
- Inventory updates between warehouses
- Automated quality checks during production
Solution: Automation developers analyze job logs, remove redundant processes, and implement parallel processing to reduce delays.
2. System Interoperability Issues Cause Data Sync Failures
Manufacturing units rely on ERP, MES, and WMS systems to coordinate production, but poor AS400 integrations often cause:
- Data lags in order processing, delaying shipments
- Inventory mismatches, leading to overproduction or shortages
- Inconsistent reporting across departments
Solution: Automation experts implement real-time API-based integrations and message queue-based event triggers to ensure seamless data flow.
3. Outdated AS400 Scripting Causes Performance Bottlenecks
Legacy RPG and CL programs that were written decades ago often contain:
- Inefficient looping structures, increasing CPU load
- Manual intervention points, slowing down automated workflows
- Redundant file processing, leading to unnecessary I/O operations
Solution: Automation developers modernize scripts, optimize SQL-based queries, and remove bottleneck-prone logic.
4. Manual Exception Handling Disrupts Workflow Automation
Manufacturers often rely on manual interventions to handle:
- Failed job recoveries
- Order processing errors
- Production recalibrations
This disrupts automation and leads to unnecessary downtime.
Solution: Developers implement self-healing automation scripts that detect and resolve exceptions autonomously, reducing human intervention.
5. Compliance Risks Due to Inadequate Audit Trails
AS400 systems often lack real-time compliance reporting, which can result in:
- Delayed regulatory submissions
- Missed quality control alerts
- Data inconsistencies during audits
Solution: AS400 experts automate compliance reporting, ensuring real-time tracking of manufacturing KPIs and adherence to industry regulations.
Conclusion
The real inefficiencies in AS400-driven manufacturing aren’t obvious – they’re buried in job scheduling, outdated scripts, and system integration gaps.
AS400 automation developers specialize in identifying and resolving these bottlenecks, ensuring a faster, cost-effective, and resilient manufacturing process.
Looking to eliminate inefficiencies in your AS400 manufacturing setup? Talk to our AS400 automation experts today!
