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The Manufacturing Trifecta

Just in case you don’t know the term, “hitting the Trifecta” is an expression used to describe the ultimate winning bet on a horse race. It refers to picking the top 3 finishers of the race, in the correct order. Since the odds against doing so are extremely low, the winning payouts are often extremely high. If you picked the right horses in the right order, a two-dollar bet could return a 4-digit payout.

Wouldn’t it be great to know which 3 horses to bet on, and in which order?

In many manufacturing companies in North America today, there are many competing ideas and priorities being considered by companies:

  • What is the most important improvement to make first?
  • What investment will yield the biggest return?
  • Which improvements will prove critical, and which ones will result in minimal, if any, gain?

There is an approach that your manufacturing company can follow to “hit the trifecta”. It’s a simple 3 step process. The first step is easy, and relatively low cost. The second step requires a bit more effort but is risk mitigated because it is based on the results delivered in step 1. The third step requires the most investment, but since it is based on the results delivered in the first 2 steps, it is not only risk mitigated, but the cost of the investment may have already been paid for by the results of the first 2 steps. Picking the order is just as important as picking the horses.

I want to show you how you can hit the trifecta in your plant.

Pulling off the Manufacturing Trifecta

Step 1 Icon that is a circleStep 1: Establish an empirical baseline to truly understand the critical “value-adding” activities on your plant floor. This is done simply by connecting your machines to FreePoint’s ShiftWorx system. It is remarkably inexpensive and can be typically be done in less than an hour without modifying the machine or your current infrastructure. Within 30 days of placing this small bet, you will not only have established an empirical baseline of your plant, but you will also have given real-time visibility to the plant that puts everyone on the same page, aiming for the same thing you are: productivity and profit improvement.

Step 2 Icon that is a circleStep 2: Engage your people in the process of improvement by using FreePoint’s Narrative software. You will now be collecting all the information you need to determine all the reasons your equipment and processes aren’t running as effectively as they should be. And more importantly than that, you will have made your people a part of the solution and improvement process, every hour of every day. They will be engaged. FreePoint’s Narrative software is embraced by workers when they conclude that management is not monitoring them, but rather listening to them. This is a powerful game-changer for many companies, especially those companies where people are their biggest input cost. Those same people can also be their biggest asset.

Step 3 Icon that is a circleStep 3: Connect your live, empirical machine data, and your fully engaged people, to your schedule and workflow plan dynamically – in real-time. Most plants use a combination of accounting systems, whiteboards, even excel spreadsheets, to plan and then report on the performance of their productivity. Some may have an ERP system deployed and some may even be considering an MES system. The problem with most ERP and MES system deployments is that it represents a single, very large bet, that will take a very long time to pay out if it pays out at all. FreePoint’s approach is to use what was gained (knowledge, insight, plus early financial payback) from the first 2 stages, tying them together in a process using visualization tools that line up with your plant’s current effective processes. Placing a bet on a system that takes years to fully implement and requires your manufacturing processes to be modified for the system to work is not just a bad bet, it’s often a losing bet.

The Outcome

factory clip art freepoint technologiesIf you are still reading, you are probably wondering how long it should take to hit this trifecta. The first step should take 30 days and should result in a payback 30 days later. The second step should take 30 days, and it too should result in a payback in 30 days. The third step should take about 120 days, but it can take as long as you like, because at that point, you will already have great empirical data, engaged and motivated people, and your system can be built to match your improved, and continually improving, manufacturing processes.

What is the expected payback on hitting this trifecta? From our experience, our customers typically see a 10% to 15% improvement at step 1, a further 10% to 15% improvement after step 2, and a 20% to 30% improvement after step 3. Doing the math, that would work out to productivity improvement, or capacity increase, of between 45% and 79%.

There it is, now you have the knowledge on which horses to bet on! Our suggestion: bet on achieving empirical data first, engaging your people second, and digitizing your plan third.

Call FreePoint to get started today.

4 Ways to Increase Production Capacity (With the Same Headcount)

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

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.

Downtime Narration

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.

Bottleneck Identification

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.

Maintenance Alerts

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.

Improvements To Productivity By Minimizing Downtime With FreePoint’s Notifications

FreePoint’s Notifications product uses the ShiftWorx platform to send out alert messages by e-mail or SMS text message when a specific machine condition has been met. These conditions are typically when a machine is off or not performing as expected.

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FreePoint and Intellacor Team Up To Reinvigorate US Manufacturing

Using ShiftWorx, Intellacor brings Industry 4.0 to existing factory equipment across the United States

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FreePoint Opens First US Office

As a growing company that strives to think globally and act locally, FreePoint recognizes the importance of establishing permanent offices closer to the major markets and customers we serve. FreePoint recently opened its first US office, strategically located in the Seattle area. With existing offices in London, Ontario and Toronto, FreePoint looked further west for the site of its next office. Seattle is a gateway to Asia and the South Pacific, where FreePoint has a growing number of customer installations, and closer to FreePoint’s existing customers in Mexico. Washington state is also a major force in the Internet of Things (IoT) market and is home to cloud providers Amazon (AWS) and Microsoft (Azure) as well as major facilities for Boeing and many other aerospace manufacturers.

FreePoint Senior Vice-President John Traynor is responsible for growing and expanding FreePoint operations globally and will be based in the Seattle office. He has lived in the Seattle area for nearly 20 years and is a member of the Washington State IoT Council. John recently spoke at the Intelligence in Data Symposium held at the University of Washington. His presentation titled “Realtime Data in Industrial IoT” addressed the importance of getting meaningful live information to people on the plant floor so they can take action right away to improve manufacturing operations.

To contact the US office, please call +1 425.979.5990 or email Email Us: info@getfreepoint.com.

US Office:

8201 164th Ave NE, Suite 200
Redmond, WA 98052

FreePoint Expands Into Soft Goods With TexTempo Partnership

TexTempo brings deep experience in textile and related industries to FreePoint ShiftWorx platform

LONDON, Ont. and ATLANTA, Jan. 30, 2019FreePoint Technologies, an award-winning provider of software for the Industrial Internet of Things (IIoT) to manufacturers worldwide, today announced that it has entered into a strategic relationship with TexTempo, a leading provider of software for labor efficiency tracking in the soft goods industries. Through this partnership, TexTempo will bring new capabilities for machine monitoring, downtime tracking, and operating efficiency to its existing portfolio of labor efficiency and payroll processing products.

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FreePoint Doubles Down On Industrial IoT Growth In Manufacturing

Company announces acquisition of CoreSolutions to address demand from customers worldwide

LONDON, Ont., Jan. 9, 2019FreePoint Technologies, an award-winning provider of software for the Industrial Internet of Things (IIoT) to manufacturers worldwide, today announced that it has acquired CoreSolutions, a software development company with offices in London, Ontario and Toronto. Through the acquisition, FreePoint will accelerate the development of its industry-leading ShiftWorx platform for machine monitoring in manufacturing while providing enhanced flexibility for configuration and customization to meet enterprise customer needs.

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5 Reasons You Need IIoT Technology In Your Factory Today

The business of manufacturing is rapidly evolving. Being coined the Fourth Industrial Revolution, or Industry 4.0, it’s all about retrieving big data that couldn’t be accessed before. By bringing the Industrial Internet of Things (IIoT) into factories across the globe manufacturers can streamline production and push products to market faster. Are you ready to gain a competitive edge?

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Recruiting Millennial Employees: How To Make Your Factory Next Generation Ready

The face of manufacturing is changing. As older workers retire, millennials (aged 18 to 35) are the biggest workforce available to manufacturers today. Is your plant ready?

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You Can Connect All The Machines On Your Shop Floor Today!

You’ve likely heard the term Internet of Things (IoT) in reference to smart home technology but how does it relate to your shop floor? In its simplest definition, IoT means “things” that are connected to the internet, physical objects such as your home, office or car. In smart manufacturing, it’s known as Industrial IoT (IIoT) or Industry 4.0, the fourth industrial revolution. It provides manufacturers with the ability to connect all machines and equipment in their plant to the internet to gather real-time, actionable data. With Freepoint, connecting machines is quick and easy on both legacy and new machines.

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