You need to track production output in real-time. What tools can help you do that?

To monitor production, a good MES system with collecting information from equipment, reporting online productivity, quality losses and monitoring the process with its inputs and outputs.

For real-time production monitoring, we extensively depend on cutting-edge sensor technologies strategically positioned along our manufacturing line. These sensors, integrated into machinery, gather crucial data on machine performance and overall equipment effectiveness, facilitating timely decision-making. The embedded sensors transmit real-time data covering aspects from units produced and equipment speed to specific product characteristics like temperature. This data is instantly conveyed to a system where it undergoes processing, transforming into numerical values and charts that offer actionable insights and intelligence.

If the entire process contains several major sub processes there can be different ways of measuring the production output. For an example in the apparel industry cutting department measures their output using the cut perimeters or number of garments depending on the auto cutting or manual cutting. In auto cutting, the machine automatically detects the total productive cut length as per the blade movements and the marker. Sewing department may measure the output using barcode systems. Some of the novel manufacturing systems use technologies like machine learning or digital twin for real time updates. And it depends on the application itself as there is no point of having expensive methods for every application.

Microsoft Power BI proves invaluable in tracking real-time production output by seamlessly collecting, analyzing, and visualizing crucial data. Through its robust connectivity options, Power BI can integrate with various data sources such as production machinery, sensors, and databases, capturing real-time information on production metrics. The platform's intuitive dashboards provide a comprehensive overview, offering insights into key performance indicators (KPIs) like production rates, downtimes, and quality metrics. Power BI's interactive and customizable visualizations enable users to drill down into specific data points, identify patterns, and recognize potential bottlenecks.

One of the most basic tools for tracking production output in real-time is the use of sensors and devices. These devices are strategically placed throughout the production line to monitor various parameters such as speed, temperature, pressure, and quality metrics. By collecting data in real-time, manufacturers can gain insights into production performance, identify inefficiencies, and take immediate corrective actions to optimize output and maintain quality standards. This proactive approach enhances productivity, minimizes downtime, and ensures timely delivery of products to meet customer demands.

Above, I shared my view on basics to move from a corrective approach to prevention. Nonetheless, prevention is more than seeing data, it will be achieved through analyzing it. So, the parameters which are now collected and stored should be put together in charts and graphs. This will unlock the potential to unveil trends, investigate issues and correlate outputs with parameters. To get there, data must be processed and your “normal” situation understood. It is important to involve and train your operation and maintenance crew in the software usage and analysis. A shift from execution to prevention, as sought. Systems must work for people, so allow warnings and andons to call attention - only to what is important (otherwise nothing will be).

Data is useful. Translating data into insights through thoughtful dashboards, is key. Software providers are out there to provide such value. However, it is up to the organization to define key metrics and frequency of receiving that data. Looking at this early (i.e. before starting manufacturing) and including this in your CapEx / OpEx plans/budget, is critical (IT infrastructure cost, equipment cost, etc).

Realmente essas ferramentas funcionam muito bem, ponto de atenção, normalmente o imput parcial da informação é humano. O equipamento detecta a parada e o imput da causa é feito por um operador e validado por técnicos, manutentores, etc. Quando for criar seus códigos de parada, é muito importante um dos códigos ser "parada em analise" assim você terá conhecimento do tempo que sua equipe leva para definir a causa correta de uma parada. Do contrário, você poderá tanto ter paradas não identificadas ou pior, paradas com causas que não refletem a realidade, mascarando seus KPIs

To track production output in real-time, the following tools are essential: 1. Sensors and Devices: Installed on equipment for continuous performance and output monitoring. 2. Dashboards and Reports: Provide real-time visualizations of production data for quick analysis. 3. Mobile and Cloud Applications: Enable access to production data anywhere, facilitating prompt decision-making. These integrated tools offer a comprehensive view of production activities, enhancing efficiency and responsiveness.

The integration of dashboards and reports that analyze data collected by our array of sensors is crucial in real time visibility. These dashboards provide a visual representation of critical production metrics, allowing for immediate insights into machine performance, equipment efficiency, and product characteristics. By leveraging advanced analytics on the data collected by our sensors, we can generate comprehensive reports that offer a deeper understanding of our manufacturing processes and promptly trigger action

Uma abordagem mais avançada para monitorar a produção em tempo real envolve o uso de softwares de simulação e otimização, capazes de modelar e aprimorar os processos de produção. Essas ferramentas permitem testar e validar diferentes cenários, como alterações no layout, configuração ou parâmetros de máquinas, adição ou remoção de recursos e restrições. Os softwares de simulação e otimização são valiosos para encontrar a solução ideal que maximize a produção, minimize os custos e atenda aos requisitos de qualidade e segurança. Essa abordagem oferece uma visão detalhada e precisa, contribuindo para a eficiência e excelência operacional.

simulation tools play a vital role, allowing us to pinpoint gaps for focused improvement areas we red on dashboard, inefficiencies with potential for improvement and then model the potential benefits of proposed improvements before implementation. This not only ensures that changes align with our production goals but also where to focus attention and resources because there will be needle shift gains

A simulação através de softwares ERP e MRP é o ideal para controle em tempo real da produção, assim como apresenta dados de melhoria continua para avanço com as implantações de metodologias Lean.

The integration of machine learning has added value in predictive maintenance. By leveraging historical data collected through sensors, machine learning algorithms analyze patterns and identify potential equipment failures before they occur. This proactive approach allows us to schedule maintenance precisely when needed, minimizing unplanned downtime and optimizing the lifespan of critical machinery.

Aqui temos sim opções robustas para controles integrados a rede, com uma boa base de dados, é possível não só acompanhar, mas prever o que está por vir e assim, agir antes de perder.

AI/ML empowers you with real-time data analysis, predictive maintenance, and quality control. Detect patterns, anomalies, and issues before they occur. Examples include anomaly detection algorithms, predictive maintenance solutions, and quality control applications using AI-powered image recognition.vent problems before they occur and optimize your business operations! Some examples of AI/ML applications include anomaly detection algorithms, predictive maintenance solutions, and quality control applications that use AI-powered image recognition. Don't miss out on the opportunity to take your business to the next level with AI/ML!

A integração dos dados gerados e a utilização da inteligência artificial para analisar esses dados é de suma importância para melhoria continua das produções que a cada dia necessitam ser mais enxutas.

For large plant operations, the integration of mobile applications is a paramount tool in tracking production effectively. These applications provide real-time visibility into critical production metrics, allowing managers and operators to monitor and manage processes remotely. Through mobile platforms. Mobile applications also enable quick response to issues, as alerts and notifications can be received on-the-go. This accessibility enhances overall operational efficiency, responsiveness, and collaboration within large manufacturing plants, ensuring that key stakeholders have the necessary insights at their fingertips to make informed decisions regardless of their location within the facility.

Com a utilização dos aplicativos e dados na nuvem possibilitando a mobilidade dos colaboradores dentro das organizações, ficou mais rápido a comunicação entre as áreas da organização, o que aumenta agilidade para tomadas de decisões, com qualidade, eficiência e eficácia.

🏭 In the dynamic world of kitchen cabinet manufacturing, tracking production output in real-time became a breeze through advanced tools. ⚙ We integrated MES that provided a centralized dashboard for instantaneous insights into production metrics. This digital solution enabled us to monitor key performance indicators, track work orders, and identify potential delays promptly. Additionally, RFID technology was employed to tag and trace each cabinet component throughout the production process, ensuring real-time visibility. 📈Embracing these tools not only streamlined our operations but also empowered us to make informed decisions swiftly, fostering a more efficient and responsive manufacturing environment for kitchen cabinets.

Herramientas para monitoreo en línea hay muchas pero definitivamente vemos una evolución importante en los procesos de manufactura que nos permiten tener ese control pasando por los PLC y ahora antes que hablar de industria 5.0 debemos entender que en muchas compañías grandes y medianas no se a sacado todo el provecho a la industria 4.0 y los beneficios de valor que pueden aportar en sus procesos y en la calidad y gestión de los mismos.

É muito importante aqui, para implantação de quaisquer que sejam as soluções escolhidas, ter o apoio e o acompanhamento da alta gerência. Sem isso, principalmente na fase de implantação, haverão muitas barreiras, culturais muitas das vezes, que vão estender sua implantação. Reuniões da alta gerência com as áreas periodicamente para avaliar a acuracidade desse acompanhamento são muito bem vindas!

"Real-time production output tracking can be a powerful tool to optimize your production processes, gain valuable insights, and improve efficiency. By carefully selecting tools that integrate seamlessly with your existing IT infrastructure, scale with your production needs, and prioritize security and data privacy, you can unlock the potential for growth and success. Remember to evaluate budget constraints and provide adequate training for your personnel, and to always strive for a tailored solution that meets the specific needs of your production environment. With these tools at your disposal, you can transform your production processes and achieve new levels of success."

To track production output in real-time, consider implementing tools like Manufacturing Execution Systems (MES), Supervisory Control and Data Acquisition (SCADA) systems, or Industrial Internet of Things (IIoT) solutions. These technologies provide live data on production activities, machine performance, and overall efficiency. MES, in particular, offers comprehensive real-time monitoring, allowing you to make informed decisions, identify bottlenecks, and optimize production processes on the fly.