An increasing number of manufacturers are using data to refine their processes. Equipment proficiencies, worker safety, and financial decisions are only a few aspects businesses are improving. Companies are leveraging technology to improve operations and remove inefficiencies. However, additional effort is needed to have proper machinery in place. The equipment’s effectiveness and potential must be optimized by collecting performance metrics.
“Data analytics and digital skills are needed to fill current job openings. Many large manufacturing firms either have begun to make or have already made great strides towards a more digitized strategy, where data from machines and products are continuously collected and used to streamline the production process,” reads research from the Manufacturing Institute.
But when it comes to production, what can be monitored and improved?
“The amount of data you can capture and monitor to progress your business is virtually limitless,” says Brian Smith, an Automation Specialist with over 25 years of experience. But it’s not just the amount of data that is now available; it is the timeliness surrounding it, Smith explains.
“In the past, you may have received weeks or months-old data. That did you little to no good. But now, with the rise of smart technology, you can get data in real time and make adjustments swiftly and easier.
Smith explains data can be collected and used differently depending on the industry, such as discrete manufacturing.
“For those machines, you typically collect information pertaining to duration and cause of machine downtime. With that data collected, workers can review the frequent reasons for malfunction and, using that, fix those problems so they don’t re-occur,” he says.
This differs from process manufacturing, where production uses refined and precise measurements.
“Typically, in those industries, you collect information such as flow rates, temperatures, and tank pressures. You can utilize that information to improve or better regulate the chemicals, food, and pharmaceuticals you may be producing,” Smith explains.
Adopting smart technology practices may be overwhelming, but Smith notes it is a journey, not a destination.
“Although it can be a significant investment to outfit your facility with sensors and other monitoring equipment, it does not have to be done overnight or all once,” Smith explains. “There have been examples of manufacturers pre-installing monitoring equipment or investing in it early, and then as they begin to roll out and expand their capabilities, they began incorporating that equipment into their daily processes.”
The financial aspect can also translate to savings through preventive maintenance and increased uptime.
“Leveraging smart technology to improve a business happens daily,” Smith explains. “Companies not only use it to improve processes, but it can also be used for preventive maintenance or planned downtime. Instead of running a motor continuously until it breaks, you can monitor it in real-time and fix any issues as soon as they appear, instead of reacting once it is too late.”
According to Deloitte, predictive maintenance increases equipment uptime by 10 to 20% while reducing overall maintenance costs by 5 to 10% and maintenance planning time by 20 to 50%.
The decision to adopt smart technology results in lucrative financial opportunities, Smith iterates.
“Let’s take a vehicle assembly line, for example. You may make 100 cars an hour, but you can collect data to make your production machines run efficiently. And now, using that data, you are making 110 cars an hour. It is a significant difference. You are now producing 10 more sellable things, and you have made yourself money,” Smith explains.
More businesses are taking note of smart technology and expect their workers to adapt. According to a survey by Rockwell Automation, at least 67% of manufacturers believe employee knowledge of smart technology is essential, valuing it as much as soft skills.
Ready to leverage smart technology to improve your manufacturing processes? Contact a CBT Specialist today.
