MES THINKING
How to unlock untapped capacity in your manufacturing operation
In today’s highly competitive manufacturing landscape, optimising production efficiency and uncovering untapped capacity are key to gaining a competitive edge. One of the most effective ways to achieve this is through the use of production monitoring software that leverages real-time machine data.
By analysing this data, manufacturers can gain valuable insights into their operations, identify bottlenecks, and unlock additional capacity and increase productivity.
Unlocking untapped capacity in your production operation can be very straightforward and machine connectivity is key to achieving that, see our Guide to Machine Connectivity. Uncovering untapped capacity can be realised regardless of the age of your machines. Let’s face it, the cost of manufacturing equipment is significant, so optimising the machinery and maximising your ROI is crutial. How to increase capacity without capital expenditure and getting more from your current operation is the goal.
One of the most effective ways to achieve this is through the use of production monitoring software that leverages real-time machine data. By analysing this data, manufacturers can gain valuable insights into their operations, identify bottlenecks, and unlock additional capacity for increased productivity.
Gaining additional manufacturing capacity
Additional capacity for a manufacturer refers to the ability to produce more output or increase production volume. It represents the untapped potential within the existing manufacturing infrastructure to meet higher demand or produce more products. The availability of additional capacity can have several benefits for a manufacturer:
- Meeting Increased Demand: If there is a sudden surge in demand for a product, having additional capacity allows you to ramp up your production quickly and fulfil customer orders without delays. It ensures that you can capitalize on market opportunities and capture a larger share of the demand.
- Expanding Market Share: With additional capacity, a manufacturer can produce more goods, enabling them to penetrate new markets or increase their market share. By meeting the needs of a broader customer base, they can enhance their competitiveness and potentially outperform competitors.
- Faster Turnaround Times: Increased capacity can result in shorter lead times and faster turnaround for customer orders. This can be a significant advantage in industries where time-to-market is crucial, allowing manufacturers to respond swiftly to customer demands and gain a reputation for reliability and efficiency.
- Flexibility and Adaptability: Additional capacity provides manufacturers with the flexibility to adapt to changing market dynamics and fluctuations in demand. They can adjust production levels, scale up or down, and accommodate seasonal variations without disrupting operations or compromising quality.
- Innovation and Product Development: With spare capacity, manufacturers have the opportunity to invest time and resources in research, development, and innovation. They can explore new product lines, improve existing products, or invest in advanced technologies to stay ahead of the competition and drive long-term growth.
Real-time machine data will help you uncover additional capacity
Real-time machine data refers to the continuous stream of information generated by machines and equipment during the production process.
This data encompasses various parameters such as machine status, performance metrics, production rates, and energy consumption.
By capturing and analysing this data in real-time, manufacturers can monitor their production activities with a greater degree of precision and responsiveness.
Traditionally, manufacturers have relied on manual data collection methods, which are time-consuming and prone to human error. And this data was always historical, so looking backwards.
However, with the advent of advanced production monitoring software, businesses can automate the data collection process and gain instant visibility into their operations.
Real-time machine data enables manufacturers to track production performance accurately, detect issues promptly, and make data-driven decisions to optimize efficiency.
Identifying bottlenecks and inefficiencies
One of the primary benefits of production monitoring software is its ability to identify bottlenecks and inefficiencies in the production process.
By continuously analysing real-time machine data, manufacturers can pinpoint specific areas where production is slowing down or encountering obstacles. These bottlenecks may include machine breakdowns, excessive downtime, suboptimal setups, or material shortages.
With this knowledge, manufacturers can take immediate corrective actions to address the issues. For example, if a machine is frequently breaking down, maintenance teams can be notified promptly to perform preventive maintenance or repairs.
By minimising downtime and maximising machine uptime, businesses can unlock additional capacity and improve overall productivity.
Optimising Production Schedules
Another way production monitoring software helps unlock additional capacity is by optimising production schedules. By analysing real-time machine data, manufacturers can gain insights into production rates, cycle times, and machine utilisation.
This information allows them to make informed decisions when it comes to scheduling production orders and allocating resources.
For instance, if a particular machine has excess capacity during certain periods, production managers can rearrange the schedule to prioritise high-volume or time-sensitive orders during those times.
By optimising the production schedule based on real-time data, businesses can minimise idle time, reduce lead times, and make the most efficient use of available resources.
Continuous improvement and data-driven decision making
Production monitoring software not only provides real-time insights but also facilitates continuous improvement and data-driven decision making.
By collecting historical data over time, manufacturers can identify patterns, trends, and performance benchmarks. This data can then be used to set targets, track progress, and drive continuous improvement initiatives.
For example, by comparing performance metrics between different shifts, operators, or machines, manufacturers can identify best practices and implement them across the organisation.
Data-driven decision making also enables manufacturers to evaluate the impact of process changes, equipment upgrades, or new technologies on production performance.
Conclusion
In the ever-evolving manufacturing landscape, leveraging real-time machine data has become a game-changer for businesses seeking to uncover additional capacity and optimize their production processes.
Production monitoring software empowers manufacturers with the ability to capture, analyze, and act upon real-time machine data, enabling them to identify bottlenecks, optimize production schedules, and make data-driven decisions.
By harnessing the power of real-time machine data, manufacturers can unlock untapped capacity, improve efficiency, and gain a competitive advantage in the market.
Overall, additional capacity empowers manufacturers to be more agile, responsive, and competitive in the market. It allows them to optimize their resources, increase productivity, and seize growth opportunities, ultimately leading to enhanced profitability and sustained business success.
Would you like to learn more?
If you’d like to learn more about how you can unlock untapped capacity, talk to one of our experts:
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How it works
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1. Book a demo
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2. Enjoy a free trial
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3. Receive ongoing support
It doesn’t end there. If you decide Intouch is the right production monitoring system for you, we’ll work with you to help you take control and make significant improvements in OEE.