23 Dec
2021

The Real Cost of Inaction: How to Achieve Manufacturing Excellence at Your Factory

You can’t predict or prevent every factory misstep, but technology can get closer. Here is how to achieve manufacturing excellence.

Food Manufacturing IIoT
OEE
OEE in Manufacturing Industry
The Real Cost of Inaction: How to Achieve Manufacturing Excellence at Your Factory
Food Manufacturing IIoT
Food Manufacturing IIoT
OEE
OEE
OEE in Manufacturing Industry
OEE in Manufacturing Industry
Food & Beverages Processing
Text Link
Text Link

Equipment breaks, team members make mistakes, and your operations get thrown off course. You can’t foresee every possible hiccup on your factory floor, but in the 21st century, you certainly can get close to seamless operations. Achieve manufacturing excellence by collecting and analyzing production data in the most efficient ways possible. The question remains: Are manual processes the way, or is there room for improvements from technology? 

 

Let’s dive into how to improve your operations, where manual and digital processes meet, and what you could lose by standing still.

How Do You Automate or Improve Operations? 

When companies question how they can improve their operations, we think of one thing: the digital factory. To improve your operations and achieve manufacturing excellence, digital factory operations can make a world of difference. Technology has opened up a whole new world. Factories can now connect all of their operations and machinery, providing accurate measurements to reveal improvement areas—from recalibrating or repairing machinery to retraining staff on processes.

Worximity’s Smart Factory Analytics

By using data analytics systems like Smart Factory analytics, teams can achieve manufacturing excellence by identifying strengths and weaknesses in their production system. Real-time data insights about uptime, downtime and bottlenecks provide actionable ways to optimize OEE. As problems emerge, teams can take corrective action, helping you boost profitability, identify and eliminate bottlenecks, increase throughput, deliver fast ROI, and more!

Data Collection and Downtime Tracking

Your operations need to run consistently—sometimes around the clock. When they don't—or can’t—you need to know why. Data collection through tools like Tileconnect helps you keep a finger on the pulse of your machinery. 

  • Event mode measures cycle time, setup time, and downtime.
  • Count mode measures production speed, number of rejects, and downtime.

Over time, the system records trends in your operations, sending insights to dashboards that reveal recurring themes in downtime—from the machinery affected to reason codes and timing.

Real-Time Dashboards

By having real-time information to refer to throughout the production process, teams increase their productivity 10-20 percent. Real-time dashboards like the custom options inside Tile+ enable workers to quickly recognize and respond to issues, maximizing your efficiency.

  • Real-time information collected by Tileconnect and generated via Tile+ dashboards identifies critical performance issues to refocus team priorities and efforts.
  • Dashboards provide options to configure KPI alerts based on specific triggers and generate KPI insights for team members to respond to in real time to increase efficiency and avoid losses.

By making your factory a Smart Factory, you can get a better understanding of hits and misses in your operations, with specific insights into why your staff or machinery may be lagging behind.

Where Do Manual and Digital Processes Fit Best?

Manual processes are always necessary to some degree, and they provide valuable insights. But they only give managers a general idea of production activities, and at a certain point, your operations need something more. 

Manually collected might be gathered in various ways depending on your staff. But this variability raises questions, such as: 

  • How much time and money do we spend to hire and train staff for these operations?
  • Are there significant staff hours required and wasted on tasks we could be doing digitally?
  • How many recording errors are staff members making?
  • How are reporting and analysis delays affecting production speed and delivery deadlines?
  • What else could technology monitor and provide insights on?

This is where digital automation can provide savings and fill in key information gaps to contribute to your continuous improvement plan. By switching to digital processes through systems like Worximity’s Smart Factory analytics, you get a clearer view of your strengths and weaknesses, plus your operations see near-immediate benefits. For instance:

  • Operating costs are lower compared to manual-only systems.
  • Automatic data collection includes broader elements, processes, and operations.
  • Real-time data brings immediate insights for teams to use to quickly pivot their activities.
  • Dashboards and analytics reports reveal otherwise-unseen improvement opportunities. 

Sluggish reporting, information inaccuracies, and limited metrics available from manual data leave operational gaps. Smart Factory analytics spotlights opportunities for improvement so you can create and implement continuous improvement plans.

Do More Resources Mean Greater Efficiency? 

The more information you have to work with, the more effective you can be. Digital automation helps you achieve manufacturing excellence because analytics and real-time data combine to show the forces that both propel and hinder factory floor efficiency. 

Digital factory tools like Smart Factory analytics measure quality, throughput, efficiency, and a whole host of essential metrics so your team can better plan improvements to maximize productivity. Collect data in real time to inform decision-making, and take advantage of cloud-based storage for historical analysis to improve your OEE and pivot to reduce downtime or equipment inefficiencies. 

Bypass the Costs of Inaction—Go Digital 

By relying solely on manual processes and analysis in your factory, you miss out on opportunities to achieve manufacturing excellence and maximize your potential. Remember, manual processes have several drawbacks:

  • Higher operating costs due to more human labor
  • Slower operations and analysis 
  • More mistakes caused by human error

Avoid these issues by trusting proven technologies and processes to highlight what’s working and what isn’t. Worximity’s Smart Factory analytics suite provides the tools and features you need to achieve your goals. Get in touch with an expert and download our Smart Factory Analytics E-book to learn how to make your factory a Smart Factory.

 

Related articles

Back to the blog
Thank you! Your submission has been received!
Oops! Something went wrong while submitting the form.
15
Nov 2023

Decoding the OEE Calculation: Translating OEE Metrics into Tangible Losses

The following OEE funnel is a great way to visualize how losses in availability, performance, and quality impact OEE and your throughput.

English
16
Oct 2023

The Synergy Between Lean Manufacturing and OEE Monitoring

Overall Equipment Effectiveness (OEE) monitoring plays a crucial role in the realm of lean manufacturing, serving as an essential tool to assess and enhance the efficiency and productivity of manufacturing processes.

English
25
Jul 2023

Breaking Down OEE for Shop Floor Success

Discover how breaking down Overall Equipment Effectiveness (OEE) into relevant metrics for the shop floor drives operational success.

English

Related articles

Back to the blog
Thank you! Your submission has been received!
Oops! Something went wrong while submitting the form.
11
Apr 2024

Votre guide en matière de contrôle statistique du processus (CSP)

En tant qu’entreprise manufacturière, il est essentiel de comprendre le contrôle statistique du processus pour survivre et prospérer dans l’environnement hyper-compétitif d’aujourd’hui.

French
10
Apr 2024

Définir la différence entre le temps de production et le temps de cycle

Le temps de cycle et le temps de production sont des indicateurs clés de la performance manufacturière. Découvrez ce que chacun signifie et comment les utiliser pour augmenter la productivité dans le cadre de votre processus de production.

French
13
Mar 2024

Moteurs d’efficacité manufacturière : Monitoring des machines et du TRG

Le monitoring des machines et du TRG (taux de rendement global) sont efficaces pour améliorer l'efficacité globale, mais quelle est la différence entre eux et qu'est-ce qui est le mieux adapté à vos opérations?

French
13
Mar 2024

Engines of Manufacturing Efficiency: Machine Monitoring and OEE

Machine Monitoring and OEE (Overall Equipment Effectiveness) are effective at boosting overall efficiency, but what is the difference between them and what is best for your operations?

English