At the end of a production run, you tally up your losses, using that data to improve the next run. After all, hindsight is 20/20…but what if you had that information much earlier? With advanced analytics, that dream becomes reality. Solutions that integrate data from multiple sources and process it in real-time help manufacturers proactively address issues during the production run, not afterward. The results speak for themselves – smoother production, fewer delays and lower costs.
Here are four reasons you should be using advanced analytics in your manufacturing environment:
- Manage Shop-Floor Operations
Using Overall Equipment Effectiveness (OEE), the gold standard for measuring manufacturing productivity, you can closely monitor equipment and make adjustments on the fly. Advanced analytics provide information on the percentage of time the production line is available to operate (availability), the speed at which the production line runs as a percentage of its designed speed and historical average speed (performance) and the accepted units produced as a percentage of total units started (quality).
- Anticipate Needs to Meet Demands
Automating your inventory process helps you reorder when supplies are running low and gauge whether you have enough inventory to meet demands. Advanced analytics help you move from reactive ordering to proactive inventory management, analyzing historical data to determine which materials you need to order more often and which materials you’re overstocking. Being prepared with the right materials also helps you eliminate supply-related production delays.
- Eliminate Delays in Production
Capturing the six big losses – unplanned stops, planned stops, small stops, slow cycles, production rejects and startup rejects – is often tedious and time-consuming. Since that data is typically collected at the end of a production cycle, you can only take action to prevent the same issue starting in the next cycle. Advanced analytics notify you of losses during the production run, enabling you to proactively address issues and improve outcomes for the current cycle.
- Minimize Production Costs
Did you know that real-time monitoring reduces manufacturing costs by 19 percent, according to SAP? By gaining insight into equipment downtime, availability metrics and the production of non-conforming parts, you can avoid sub-optimal performance and losses that damage your bottom line. Integrating your data into a holistic, easy-to-understand format makes it simple to spot the parts of your process that are driving up costs and take immediate action to repair those weak points.
With a dedicated focus on SAP’s Leonardo OEE technologies, Dickinson + Associates deploys enterprise-level solutions that help manufacturers leverage advanced analytics for a competitive production experience. Contact us today to optimize your manufacturing process and start your digital transformation.