The manufacturing industry is constantly evolving and one of the most significant changes in recent years has been the increasing use of online software to monitor production processes and reduce machine downtime. The growing popularity of Industry 4.0 is beginning to force manufacturers to digitize their production lines, as customers are increasingly ordering smaller batches of products. Manufacturers need to be able to adapt quickly to these changing demands. One of the key benefits of using online production monitoring software is that it allows manufacturers to identify and diagnose problems in real time. This not only minimizes downtime but also maximizes productivity.
“The growing popularity of Industry 4.0 is beginning to force manufacturers to digitize their production lines, as customers are increasingly ordering smaller batches of products.”
Benefits of Online Production Tracking
Cloud-based production monitoring systems are becoming the successors of Manufacturing Execution Systems (MES) due to their various benefits:
#1: Real-Time Downtime Tracking
Real-time downtime tracking is one of the major benefits of using online production monitoring software. The implementation of such a system often does not require a complex process of adaptation or changes to the production line. The system, most often offered as SaaS, can integrate with machines, and monitor all necessary signals from the line. This allows manufacturers to take immediate action, minimizing downtime and thus maximizing productivity. Many line losses result from problems that operators cannot easily observe. Advanced production monitoring systems report downtime and point out the machine that caused it, showing the specific problem.
On the other hand, if a machine is producing bad quality products, the system can alert the operator, who then takes appropriate action to resolve the problem and get the machine back in operation as quickly as possible. This is crucial for manufacturers as it allows them to maintain the quality of their products and ensure customer satisfaction.
#2: Short Changeovers
Another important aspect of production optimization is the rapid changeover of the production line. This is when a manufacturer needs to move from producing one product to another, and it can be a time-consuming and costly process. However, by using online process monitoring software, manufacturers can optimize their changeover procedures, reducing the time and costs associated with the process. Currently, this is one of the biggest challenges for manufacturers. What’s more, such systems monitor the OEE indicator, reporting in real-time how a shift has performed.
#3: Deep Dive Reports
Deep dive reports are another important benefit of using online production monitoring software. A production monitoring system can help manufacturers track and analyze production data, providing valuable insight into their operations. With advanced reports, which are often tailored to the needs of a particular company, it is easy to track production starts and analyze their causes. This allows manufacturers to identify areas for improvement and make data-driven decisions to optimize their operations.
Additional Functionalities: Video Monitoring & Orders Automation
Line video monitoring allows manufacturers to remotely monitor their production in real-time. This allows them to identify and diagnose problems faster and in areas where shop floor workers wouldn’t spot them. In addition, video monitoring also helps to improve the overall safety and security of the production line. Production line video monitoring can also monitor the condition of equipment and alert operators at the right time.
Importing production orders from excel or MES, on the other hand, helps to streamline the production process. By importing production orders directly into the software, manufacturers can easily manage their production schedules and even automate some states like ending changeovers. This is a benefit that speeds up production. These two functionalities also help to improve communication between different departments such as production, maintenance, and logistics. This is critical for manufacturers as it allows them to make data-driven decisions.
The Successor to MES
Cloud-based production monitoring systems are becoming the successors of Manufacturing Execution Systems (MES) as they provide similar functionality at a lower cost and implementation time. They are also more flexible and can be easily integrated with other systems and software. This makes them more accessible to small and medium-sized manufacturers, who may not have the resources to invest in large and expensive MES implementations.
In summary, production monitoring programs are likely to become the standard in modern manufacturing in the coming years. Their cost and implementation time give them a significant advantage over large and expensive MES implementations, providing manufacturers with valuable insight into their operations. This allows manufacturers to optimize their operations, reduce costs, and improve the overall quality of their products. With the increasing demand for smaller batches of products, online production monitoring software is becoming an essential tool for manufacturers to stay competitive in today’s market.