Optimizing production efficiency is important for manufacturers that are looking to maximize profits. The key lies in minimizing the six big losses that plague production lines: set up time, break down time, reduced speed, short stops, process waste, and out of spec product. By understanding and systematically addressing each loss area, manufacturers can unlock substantial gains.
Tackle the Following six big Losses; Boost Your Production Efficiency
1. Set Up Time Loss
A lot of time can be wasted during machine setup and changeover. This not only eats into production capacity but also leads to losses and inefficiencies. As manufacturers aim to meet growing demands and stay competitive, it’s crucial for them to find ways to cut down on setup time, make their operations more streamlined, and boost their output.
The answer to this problem is to create and use strategies that make the setup processes quicker. These strategies, often called ‘quick change setups’ or ‘quick tooling changes’, aim to switch from making one product to another as swiftly and smoothly as possible. But, making these setup processes faster isn’t always easy. It needs a good grasp of the machines, tools, and workflows used. Experts might need to step in to find and fix any hold-ups. One popular strategy is to use a method called SMED (Single-Minute Exchange of Die), which involves closely studying the process and turning internal changeovers into external ones.
Rapid Deployment Services
This is where Shoplogix comes in. Shoplogix provides a comprehensive solution that helps manufacturers reduce setup times and streamline operations. Their rapid deployment service offers quick and cost-effective machine connectivity, enabling manufacturers to install and configure software quickly and easily. They also provide necessary training as part of their package, ensuring that the manufacturing team can effectively leverage the new tools and processes.
2. Break Down Time Loss
Breakdown time can lead to significant losses in terms of production output and costs. Every minute a machine is not running equates to lost production time, which can quickly accumulate. Furthermore, unplanned downtime often necessitates expensive emergency repairs.
To address this, companies need effective strategies to minimize breakdown times. This could include preventive maintenance to identify potential problems before they result in failures or establishing systems for quicker repair response times when breakdowns do occur. Shoplogix offers a Smart Factory Suite that enables companies to connect, collect, store, analyze, and take action on their shop floor data, thereby enhancing their ability to manage and mitigate machine downtime.
3. Reduced Speed Loss
When machines run slower than their optimal rated speeds, underproduction occurs. Continuous monitoring of asset utilization through IIoT connectivity can help optimize machine speeds sustainably. Shoplogix’s platform provides this kind of asset monitoring and Overall Equipment Efficiency (OEE) tracking in real-time, enabling manufacturers to optimize their operations and reduce speed loss.
4. Short Stop Loss
Frequent short stops, even those only lasting seconds, can add up over time and significantly impact production. By tracking and analyzing these stoppages, their root causes can be identified and eliminated, maximizing runtime. Shoplogix’s OEE software provides the necessary visibility by automatically tracking every stoppage, helping to reduce short stop loss.
5. Process Waste Loss
Inefficient processes can result in waste of raw materials, energy, and water. Continuous optimization of these processes through data analysis can minimize such losses. Shoplogix’s analytics dashboards reveal trends in process efficiency, providing insights that can drive significant improvements and reduce waste.
6. Out of Spec Loss
The production of scrap parts does not contribute to sellable output and represents a loss for manufacturers. Predictive analytics using machine data can help prevent out-of-tolerance operation, reducing scrap rates. Shoplogix’s Quality module uses this approach to detect anomalies and predict failures, helping manufacturers reduce out-of-spec loss.
About Shoplogix
Shoplogix provides manufacturers with real-time visibility into hidden production potential on the shop floor. Insights gained with Shoplogix analysis and reporting software reduce operating costs, increase manufacturing profitability and drive rapid time to value.
Shoplogix is designed to increase operational efficiency, improve quality, and drive higher levels of performance in all types of manufacturing environments. Clear graphical displays provide immediate visibility into loss areas, without the need to analyse any reports. This visibility facilitates immediate improvement actions.
Final Thoughts
With well-integrated software solutions like Shoplogix’s smart manufacturing platforms, manufacturers gain tangible control over their operations. They enable harnessing the wealth of machine data with applied analytics to minimize the impact of the six big losses substantially. This unlocks untapped OEE potential within existing production lines without significant capital expenditure. The gains directly enhance profit margins and competitive advantage for manufacturers willing to embrace this smart evolution.
