Industry 4.0 – Are you ready to lead the race?

Industry 4.0 – Are you ready to lead the race?

Industries are now racing towards Industry 4.0. It is the future of productivity and growth of manufacturing Industries. The advancement of manufacturing technology is the hallmark of this revolution that can communicate and cooperate in real time between themselves and humans. The production reality in today’s increasingly competitive world demands efficiency and quality with continuous and improved processes while embracing the Industry 4.0. In order to stay competitive and succeed in the race, you have to push yourself to measure manufacturing productivity right. Hence, deploying an outright production monitoring software PaceDPR, that provides a real-time view of the shop floor will help you optimize your production flow. This article provides detailed view on how to gain momentum in Industrial race using OEE manufacturing system, PaceDPR.

Bird’s Eye view on production

The production process in the manufacturing industry can be optimized only when the production environment is provided with real-time data. The real-time monitoring can increase the operational productivity level by 50%. PaceDPR is an extremely efficient and effective tool that is designed to provide the real-time view of your complete shop floor. The real-time status will help you fairly understand the manufacturing process & reckon OEE pertinent to availability, performance & quality. The real time visibility on production will augment your focus on productivity & betterment activities & help you eliminate inefficiencies & bottlenecks.

Effective performance visualization

PaceDPR has been designed to guarantee perfect visualization of all the performance parameters and indicators collected from the production system using the real-time data dashboard displays and analytical reports. These tools are designed to offer transparent and accurate OEE manufacturing data with all the information needed to reduce production loss. The performance of the overall machines and the performance of each machine in a current day can be viewed separately as needed. This will help you analyse the productivity of each machine to overcome the production loss. The reports for analysing data collected can be archived by shift based cumulative reports & hourly production reports. This will allow you to discover the real production capacity of systems, production lines and machinery and will less the equipment maintenance cost by 25%. You could look deeper into the performance of each machine for deeper analysis and decision-making.

Tracking Manufacturing Downtime

Generally production environments are subject to various causes such as machine malfunction, downtime, failures and rejects that weakens the overall performance of machines, reduces production efficiency, causing economical loss to the Industry. Almost every Industry loses 5 to 20% of its productivity due to downtime. Hence it is necessary to understand the actual cost of downtime and ways to reduce it. However, the performance indicators & OEE manufacturing data alone are not sufficient to detect the causes of inefficiencies. The precise tracking of downtime events is essential to prevent and manage the excessive loss. Pace DPR will provide you an exact view on production line & help you identify bottlenecks, maintenance issues & other events that cause downtime. This information is essential to ascertain what and where the causes of inefficiency are in order to remove them. This helps you analyse the reason behind downtime that occurs due to set up, raw material shortage, scheduled maintenance, meetings and work breaks. By managing the downtime, the productivity loss and inefficiency can be lowered.

Take complete control over machines

PaceDPR best suits the Industries that run in single and multiple shifts. The evaluation and monitoring of machines can be done based on your shifts and the ideal cycle time of machines. You will be able to update your machine details to understand the performance in relevance to machines.

PaceDPR is the simplest & affordable solution designed to aggregate production information and makes it available to production managers with great clarity and simplicity. This will help you close the gap between production processes & planning & will help you lead the industrial race.

Talk to our experts to discuss about your requirements at your shop floor to improve your manufacturing productivity.

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Impact of Downtime in Manufacturing

Impact of Downtime in Manufacturing

The adage “Time is Money” holds true in every business & manufacturing processes. In Manufacturing Industries, every second of machine running earns money. The more time it takes to convert raw material into product, the more money it costs to get it out. What will happen if your machines sit idle for a long time?. There will be a chance of facing revenue loss. This unexpected or unplanned outage duration is known as Downtime. This article provides a detailed view on the downtime, its impact in manufacturing process & how to reduce the downtime.

Actual Cost of Manufacturing Downtime

No Industries wants to face Downtime. It is the awful nightmare for every Industry out there. A common estimate is that almost every industry loses 5 to 20% of its productivity due to downtime and the costs can be outrageous. Machine Outages can bring production to a screeching halt and it costs an industry millions of dollars. This startling data shows how costly the downtime can be. Hence, the financial cost of downtime is crucial for every manufacturing industry. Unplanned outage can lead to a substantial cost with an extensive impact on industry’s bottom line. Disregarding the cost of downtime isn’t an option & reducing the downtime is decisive for business’s bottom line. In order to satisfy financial goals & to keep the bottom line strong it is necessary to understand the actual cost of downtime & the ways to reduce it.

Why do Machines Sit idle?

The causes of Downtime can be Tool breaks, Machine faults, Process failure, unplanned stops etc. While downtime is most often associated with breakdown it is actually an unplanned event that seriously affects your manufacturing process. Unplanned downtime includes, excessive changeovers, lack of operator, & unplanned machine maintenance. In order to deal with it, it is requisite to understand each downtime & how it impacts your industries’ profitability.

Tracking Manufacturing Downtime

Tracking how, when, where the downtime occurs will help you prevent & manage the excessive loss. An early step towards minimizing downtime is possible only when it is tracked precisely & cautiously. The traditional way of obtaining data that involves log sheets in which operators manually log the downtime will frequently miss the downtime events. Hence, utilizing complete monitoring software that provides real-time view of shop floor will significantly provide the data on downtime events. OEE DPR, the powerful software to measure manufacturing OEE will provide you an exact view on production line & help you boost inefficiencies, identify bottlenecks, maintenance issues & other events that cause downtime. Recording the downtime & identifying the reason for downtime will significantly reduce the production issues & increase the production rate.

Analysing the data

Unplanned downtime and breakdown losses are concerned with availability. Hence measuring OEE is a key driver to eliminate production loss & to have a better understanding on production. But measuring OEE & collecting data alone will not help you improve your production. Developing the strategic enrolment plan by analysing the gathered data to reduce the amount of downtime is decisive. OEE DPR will help you analyse the data & understand the reason for downtime and how the obtained data can be applied to improve predictive maintenance.

The metric that didn’t tie up with the straight data from machines will not provide you an accurate picture on your production loss. The real-time data view of what’s going on in the production line will provide you a real context to the downtime events. Thus OEE DPR will ultimately give manufacturers the potential to get away from production issues and towards a more data-driven business.

We will be happy to discuss about your requirements at your shop floor to help you reduce downtime & improve your productivity.

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