For any business, the process of implementing any new technology can often seem like a costly and time-consuming task. Industry 4.0 and machine monitoring is no exception.
Emerging technologies and existing technological advancements are paving the way for a revolution in the manufacturing industry; but how much does being a part of this revolution cost? Well, that depends on the technology.
Why Bolt-on Solutions Are Less Expensive
Unlike robotics, AI and fully automated factories, machine monitoring is relatively inexpensive. Instead of the intensive and often costly installation of AI and robotics, machine monitoring can be installed with minimal cost and disruption to machine operations. Rather than having to alter or rebuild existing infrastructures, bolt-on monitoring solutions like our ShiftWorx Platform are bolt-on, making them extremely simple to incorporate on the shop-floor.
By installing our hardware without disrupting machine production, we can provide a cost-efficient solution that saves you money and never contributes to machine downtime. By maintaining a low overhead cost, our solutions also experience impressively quick ROI. In fact, one of our clients managed to achieve an additional +160 hours of machine output per month—both saving and making them a lot more money in the process.
When manufacturers are asked what their plant utilization rate is, most plant managers give an answer anywhere between 65-75%. In most cases after machine monitoring is implemented, the actual percentage is revealed to be closer to 25-32%. That massive variance illustrates how quickly machine monitoring solutions can help manufacturers save on production costs, helping payoff the system in days rather than months and years. Once switched on, machine monitoring solutions instantly start paying themselves off.
Overall, transitioning to IIoT doesn’t have to break the bank. By piggy-backing off existing infrastructures as opposed to rebuilding them, machine monitoring can be an attainable and inexpensive means of innovating your production process and enhancing your plant’s productivity.
Get a free quote today and find out for yourself how attainable IIoT can be for your organization.
FreePoint is excited to be taking part in this year’s Best Manufacturing Apps Conference (BMAC). Hosted by Microsoft Canada partner, VOX ISM, BMAC unites Canadian manufacturers and industry experts, educating them on the latest in digital transformation technologies.
In addition, our President, Paul Hogendoorn is taking part in a panel of technology suppliers addressing industry leaders and manufacturing professionals. As always, FreePoint is excited to be displaying our non-invasive machine monitoring software and hardware solutions.
According to Vox ISM, there are 3 main reasons you should be attending the 2019 BMAC conference:
- Interact with BMAC exhibitors showcasing their latest technologies.
- The BMAC is recognized as the best platform for Canadian Manufacturers to interactions with the latest trends in the manufacturing industry.
- Experience and envision the business relationships being made and developed with prospective exhibitors of your interest.
If you would like to attend this years conference, you can register here.
For many manufacturers, increasing efficiency and production capacity is the primary focus. However, where the challenge really lies is in increasing production capacity without hiring additional staff or purchasing more machines.
Fortunately, manufacturers can leverage industry 4.0 as a driver for growth as well as productivity; with machine monitoring technology, you can unlock the full potential of your factory, and those who operate within it.
Machine monitoring provides a long list of benefits to manufacturers, these benefits result in increased production capacity and increased profitability. For a real world example, a client of ours managed to improve overall efficiency by a 69% in just 1 year – saving roughly $325/day without increasing personnel or machines.
Read below to learn the 4 ways to increase productivity without hiring new employees or procuring new equipment.
Employee engagement through machine monitoring is focused on inviting collaboration between management and machine operators. It is not a “big-brother” tactic, quite the opposite actually, by showing employees how their contribution affects the big picture, you help unite management and plant employees working towards the same goals.
Using visualized dashboards, employees can easily see their role in the manufacturing process from a data perspective – which helps them fully realize the value of their contribution. This can even evolve into a “gamified” environment, as employees compete to see who can be most productive. This encourages employees to constantly improve, as they can now view their performance in real-time.
Machine monitoring allows for real-time narration of downtime, another way a manufacturer can leverage IIoT to increase production capacity, without increasing headcount. Not only is downtime narration critical for plant managers seeking seamless production, it’s also a strong motivator for employees as well. Obtaining insight into what causes delays allows employees to better understand the impact of any delays in their work station.
It’s important to understand all data is good data. Even unexpected downtime or broken machines can give you valuable insight into your process. With proper real-time narration, managers can identify and mitigate root causes of machine downtime, as well as highlight strong points in the production chain.
Like we mentioned earlier, machine monitoring provides valuable insight into your manufacturing processes, one of those insights is bottleneck identification. When one process is being delayed due to another person or machines performance, you know exactly where along the workflow the delay is occurring – empowering you to address the problem in real-time, and create fixes to prevent it from happening in the future. By proactively identifying holdups in your process, you are better positioned to make actionable changes to your workflow that will increase both efficiency and productivity.
Machine monitoring also enables a more proactive approach to machine maintenance. Rather than having to wait for someone to notice a machine is broken, then communicate that to management, you can get real-time alerts as issues arise. That means a significantly faster response time when a machine unexpectedly goes down, and a much quicker fix. It all comes down to maximizing machine uptime, the more value-added time that a machine contributes, the more efficient your plant becomes.
Are you ready to Increase your Production Capacity without Adding more People or Machines?
With FreePoint’s globally deployed solution, manufacturers are seeing near-immediate benefits to their processes. Increased efficiency, mitigated machine downtime, and improved employee engagement are accessible benefits to all those willing to shift into the IIoT world. Machine monitoring not only helps management make more informed decisions, it also provides real-time visibility into individual contributions and the entire production process overall.
If you’re interested in saving time and money, being proactive about your machine maintenance, and gaining total transparency into your entire production process, you should consider making the transition to industry 4.0.
The worst enemy of any manufacturer is machine downtime. How to control and mitigate downtime is a constant battle for manufacturers trying to increase efficiency and maintain peak production. At FreePoint, through machine monitoring and production tracking technologies, we work with manufacturers to minimize downtime as much as possible, while maximizing machine output.
One of the ways we help manufacturers control their machine downtime is with Reason Codes, the backbone of downtime narration in our ShiftWorx platform. When a machine becomes idle, operators can apply a reason code to categorize that downtime period. Rather than seeing a machine offline for 20 minutes with no explanation, plant managers can see in real-time what the cause of the delay is— and address it. Those small increments of time add up, 10 minutes here or there can be worth over 6 figures in a year.
Using Reason Codes, you can:
- Diagnose Machine Downtime Causes and Apply Solutions
- Alert Decision Makers in Real-Time to Plant Floor Issues
- Identify Machine Maintenance Needs
- Empower Employees to be Part of the Solution
Identify Downtime Causes
With reason codes, employees and managers can easily identify factors impacting machine downtime. Whether the reason is “waiting on materials” or “needs repair”, everybody is made aware of what factors are contributing to delays— valuable data for plant managers seeking to increase efficiency and achieve seamless production in real time. If someone has transparency into delay causes, they are more motivated to solve the cause of the delay. This makes the overall process more efficient and engaging.
Keeping Everyone in the Know
Reason codes also help mitigate machine downtime with real-time alerts. When reduced productivity or machine delays are detected, notifications are sent to all devices connected to our ShiftWorx platform, through SMS or email. Real-time alerts increase response time to problems that impact production—meaning solutions are found faster, and the length as well as the frequency of downtime can be decreased.
Identifying Downtime Patterns
By comparing actual performance to projected performance, you can benchmark productivity against past data to identify opportunities for improvement. A recurring reason code could indicate a machine issue in need of maintenance, or another machine consistently causing delays. Identifying these factors better positions plant managers to rectify them and prevent them from happening in the future.
It is important to understand that all data is good data. Even un-anticipated downtime, machine breakdowns or inefficient scheduling can give you crucial insight into your operation. When machine monitoring hardware works in tandem with data visualization, you can see every performance detail from any machine, regardless of industry or age of machine.
Schedule a demo today and learn what ShiftWorx can do for you!
The transition to industry 4.0 can seem daunting at first. How much will it cost? How will it fit my process? How long will training staff take? All common questions we get asked from manufacturers. The most common question we get asked is “how soon can I expect an ROI?”. Luckily, the answer is simple: VERY SOON. In fact, one client of ours managed to save $300 per day as a direct result of our machine monitoring, which allowed the system to pay itself off in less than a month.
Manufacturers and industrialists in every sector are on the threshold of significant change. Industry 4.0 is the newest industrial revolution. It represents the use of Industrial Internet of Things (IIoT), automation, sensor technology, and other innovative solutions to streamline the production and distribution process.
IIoT solutions not only monitor but also automate many of the complex processes involved in manufacturing. While systems have been created in the past that track production progress, IIoT technology focuses on providing in-depth details to managers and staff. Here are seven compelling ways IIoT is transforming the industry today.