- Graphical & Tabular Hourly Production Data
- Dashboard accessible from ANYWHERE, ANYTIME
- Daily Email Report with the Overall Summary & Machine wise Hourly Production Summary
- Optional Consulting Support
IOT BASED CLOUD CONNECTED PRODUCTIVITY/OEE MONITORING SYSTEM:
Snapshot of PMS:
Snapshots of Productivity Monitoring System:
Case Study:
Problem:
An automobile parts manufacturing company was facing low efficiency issues with machines due to the paper-based approach for tracking machine utilization, which left room for error, leading to unreliable data around true capacity.
AS-IS Situation:
Paper-based system to track machine downtime is inaccurate and costly:
Each year, this Company evaluates improvement opportunities within the company’s production line against machine capabilities and capacities. To arrive at an estimate of minutes ran, this Company relied on a paper-based system where supervisors recorded machine down times every business day across 50+ Lines and 3 shifts. “Those downtime logs were always 5, 10, 15 or 20 minutes—it wasn’t very accurate,” reliable sources report. “Without precise data, we never really knew how much capacity we had on the shop floor, so we kept asking for more resources to work more.” Instead of continuing the paper system, Management began looking for a technology solution that would deliver reliable data, without the need
for extra investment in sensor hardware.
Paper-based system to track machine downtime is inaccurate and costly:
Each year, this Company evaluates improvement opportunities within the company’s production line against machine capabilities and capacities. To arrive at an estimate of minutes ran, this Company relied on a paper-based system where supervisors recorded machine down times every business day across 50+ Lines and 3 shifts. “Those downtime logs were always 5, 10, 15 or 20 minutes—it wasn’t very accurate,” reliable sources report. “Without precise data, we never really knew how much capacity we had on the shop floor, so we kept asking for more resources to work more.” Instead of continuing the paper system, Management began looking for a technology solution that would deliver reliable data, without the need
for extra investment in sensor hardware.
Dip stick study:
Trial run of Felidae Systems Productivity Monitoring System Solutions Yields 75% machine utilization:
This Company began its engagement with Felidae Systems with a two-month trial, collecting production data from two lines to better understand true capacity. For the leadership team, the proof of concept demonstrated the value of data-driven decision making and showed that the way forward was digital. “With Proefficient, it was shown exactly what happened on any date, within seconds,” said the Corporate representative.
“There’s no guessing or looking through piles and piles of paper and entering of that data into excel for further analysis. Felidae showed that the Client can’t run away from data—it’s telling exactly what client needs.” Before the trial run, machine utilization was estimated between 50–60 percent; after the trial it was 75 percent, When the system is implemented for whole plant the machine utilization is 99%. “Every second, every minute, and every hour were accounted for—no supervisor can do that 24/7 for every single second,” decision makers said. “Now we’re making data-driven decisions and achieving higher utilizations from machines with the optimized resources.”
Challenges:
1) High response time of information flow from shop floor to top management.
2) No reliable and authentic reports.
3) High downtime.
4) No visibility of Production and Efficiency at Shopfloor.
Solution Implemented:
- Production Monitoring Systems was implemented to yield machine utilization and record break down hours and respective reasons.
- It is a real-time cloud based robust systems to capture machine efficiency.
- Real-time data visibility through centralised portal, which can be accessed from anywhere, any time.
- Breakdown & Quality HMI mounted at each machine and the various Andon Systems and IO devices installed on shop floor that allow shop floor workers to view and add additional context to utilization data. The Breakdown & Quality HMI captures downtime reasons, rejection reasons and more.
Benefits:
- Increased Capacity Utilization- Company has achieved 99% of Machine utilization after implementation of PMS.
- Reduced Paperwork and Data Entry Work- No guessing or looking through piles and piles of paper and entering of the data into excel for further analysis. Solution provides the real-time insights.
- Precise & Optimized Data Driven Planning- Management is making data driven decisions and achieving higher utilisations from machines with the optimised resources.
- The benefit of implementing a plug-and-play Internet-of-things (IoT) platform is that Management can embark on digital transformations without dedicated IT resources in-house.
- System captures real-time downtime codes, which are centrally tracked and visible to all. It establishes the accountability of all contributing to value chain system and helps to take corrective
and preventive actions proactively.
Testimony:
The Felidae Systems delivers real-time insights. For manufacturers, the benefits of implementing a plug-and-play Internet-of Things (IoT) platform is they can embark on digital transformations without dedicated IT resources in-house. “The beauty of our solution is that it’s an as-a-service model”. “Manufacturers do not have the time nor do resources to rebuild the wheel from scratch and neither do we. By leveraging powerful services & solutions, we can focus our efforts on developing our
unique intellectual property to deliver the most secure, high-performing, resilient, and scalable platform for machine data and applications. For our customers, it’s a far better use of their manufacturing resources than building a solution themselves.”
Andon System bring unprecedented visibility into shop floor.
Included in the Felidae Systems Industrial Automation Solutions are Breakdown & Quality HMI mounted at each machine and the various Andon Systems and IO devices installed on shop floor that allow shop floor workers to view and add additional context to utilization data. The Breakdown & Quality HMI captures downtime reasons, rejection reasons and more. At this Compny, the HMI have been instrumental.
Included in the Felidae Systems Industrial Automation Solutions are Breakdown & Quality HMI mounted at each machine and the various Andon Systems and IO devices installed on shop floor that allow shop floor workers to view and add additional context to utilization data. The Breakdown & Quality HMI captures downtime reasons, rejection reasons and more. At this Compny, the HMI have been instrumental.
Outcome Snapshots:
Benefits:
- OEE is the primary indicator for Productivity. Real Time monitoring when data is directly fetched from Machines eradicates the chances of inconsistency, delay and manipulation resulting in TRANSPARENCY.
- Due to the Shop Floor now being virtually visible there is a sense of alertness in the Shop Floor Employees which enhances their PERFORMANCE & DISCIPLINE.
- Observe how changes in relevant Driving Factors impacts
- Artificial Intelligence will help in Sustaining the Results.
- Eliminates manual inconsistent process of noting data in books thereby ReducedPAPER-WORK & DATA ENTRY WORK.
- Cloud accessibility: Access digitally, from ANYWHERE ANYTIME and hence EASE OF ANALYSIS
Set responsibility with ACCOUNTABILITY and BENCH-MARKING for PRODUCTIVIY
Snapshot of OEE:
