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.


Impact of Downtime in Manufacturing

Impact of Downtime in Manufacturing

In any business and production process, the saying “Time is Money” holds true. Every second that a machine is running earns money in the manufacturing industry. The longer it takes to develop raw materials into finished goods, the more money it costs to get them out. What will happen if your machines are left idle for an extended period of time? There is a possibility that revenue will be lost. Downtime refers to the duration of an unplanned or unexpected outage. The Ignition OEE Downtime Module enables manufacturers to identify problem areas in a production line or across an entire business. This extensive understanding into the topic of downtime, its impact on the production process, and ways to minimise it.

Actual Cost of Manufacturing Downtime

Downtime is something that no industry likes to deal with. Every industry in the world is living in a nightmare. According to one estimate, practically every industry loses 5 to 20% of its production due to downtime, with the expenses being outrageous. Machine failures can bring production to a halt and cost a company millions of dollars. This surprising statistic demonstrates the high cost of downtime. As a result, every industrial industry must consider the financial cost of downtime. Unplanned outages can cost a lot of money and have a major impact on the industry’s bottom line. It is not an option to ignore the expense of downtime, and limiting downtime is critical to a company’s bottom line. To meet financial objectives and maintain a healthy bottom line, it’s important to understand the true cost of downtime and how to minimize it.

Why do Machines Sit idle?

Tool failures, machine faults, process failures, unplanned stoppage, and other factors can all contribute to downtime. While most people associate downtime with breakdowns, it is actually an unplanned event that has a significant impact on your production process. Excessive changeovers, a lack of operators, and unplanned machine repairs are all examples of unplanned downtime. To deal with it, you must first understand each downtime and how it affects your industry’s revenue.

How to Calculate Downtime for Equipment:

Because this term can refer to any event that causes a halt in manufacturing, it’s critical for a company to first determine what kind of downtime they want to calculate. Assume a factory is experiencing some issues with machines failing. They’ve determined that this is the majority of their downtime, making it the most important type of downtime to track. One method for calculating the cost of equipment downtime is to consider the revenue lost during downtime periods. We can do this by comparing the number of products produced in a given time period (per hour) to the amount of money made from each product. Then we compare these figures to the amount of downtime that has occurred.

According to this equation, if we produce 20 units per hour and profit $100.00 per unit, each hour is worth $1000. If we have 4 hours of downtime, we have lost $4,000.00 in just those 4 hours. Consider how much revenue can be lost if the downtime is longer or the product is more profitable. It’s easy to see why this is so critical to track down and fix as soon as possible.

Tracking Manufacturing Downtime

You can prevent and control excessive loss by tracking how, when, and where downtime happens. Only when downtime is measured carefully and thoughtfully can an early start toward minimising it be taken. The typical method of obtaining data, which includes operators manually recording downtime on log sheets, usually misses downtime incidents. As a result, adopting comprehensive monitoring software that provides a real-time view of the shop floor will provide considerable data on downtime situations. OEE DPR, the powerful software for measuring manufacturing OEE, will give a clear view of your production line and help you detect inefficiencies, determine bottlenecks, maintenance concerns, and other downtime-causing events. Recording downtime and determining the cause will drastically decrease production issues and increase the rate of production. Reducing the amount of time that people or machines sit idle will improve the bottom line of the company. Take a look at the suggestions below for reducing manufacturing downtime.

  • Regularly provide safety training to limit the risk of dangerous user errors.

  • Make a dependable preventive maintenance schedule.

  • Establish a routine for inspecting critical equipment.

  • Keep track of equipment lifespan to determine when it’s time to upgrade.

Analysing the data

The availability of a system concerns unplanned downtime and breakdown losses. As a result, evaluating OEE is a critical factor in eliminating production losses and gaining a better understanding of production. However, simply monitoring OEE and gathering statistics would not help you increase your output. It is critical to develop a strategic enrolling plan based on the acquired data in order to reduce downtime. OEE DPR will help you in analysing the data, determining the cause of downtime, and determining how the information acquired can be used to improve predictive maintenance.

The metric that does not correlate with machine data will not provide you an accurate view of your production loss. The real-time data view of what’s happening on the manufacturing line will give the downtime events in context. As a result, OEE DPR will allow manufacturers to move away from production difficulties and toward a more efficient manufacturing process. As a result, OEE DPR will allow manufacturers to move away from production difficulties and towards a more data-driven business model.

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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