You're facing production delays. How can you harness technology and automation to prevent them in the future?

Production delays are subjective & are mostly dependant on type of industry you are refferring too. For most of the FMCG industry mostly automation & slight usage of data anlytics objectives can be met once ur proto run is successful during development stage. Real challenge occurs when your customer also is unaware of the output expected from the given order to meet the end result. So agile methodology to breakdown large objectives in smaller one helps u to meet the output as well as to resolve production delay at large. Each skilled team member must be aware of their task independently to contribute as whole against the given timeboxed activity.

Tendencies in addressing production delays are usually focused on product and process. This approach is good, but may fail to address core reasons behind delays. Human factors like motivation & training. Over conservative safety implementation. Inventory, handling, supply chain, etc... The starting approach I would suggest is: 1-Conduct in depth stakeholder surveys to get insights about direct and indirect causes 2- Conduct full RCA of the work environment 3-Request improvement ideas from all stakeholders. Only then you can start assessing any investments of time or capital for improvements. Using technology to collect, sort and analyze data, capture reality and control process are essential yet secondary to sound approaches of assessment.

We can Reduce Time cycle of batches or production by increasing batches volume as per Reactor Capacity also by doing minor changes in transfer/ Receiving Lines and pumps. Also by doing proper preventative maintenance of our equipment such as pump seal,Push button,electrical equipment. Some time we done reaction and cooling in same vessel for that we can think of other options.

Form a Cross-functional team...map the process flow with as is condition...start capturing data activity wise...focus on NVA's...start implementing ANDON boards/lights/alarms to alert people regarding the delays.

By implementing predictive maintenance tools, organizations can transform their maintenance approach from reactive to proactive, reducing machine breakdowns and increasing overall efficiency. Predictive maintenance (PdM) uses advanced technologies like IoT, AI, and machine learning to forecast equipment failures before they occur. By leveraging real-time data from sensors and machines, PdM tools enable proactive maintenance, reducing downtime and increasing overall efficiency.

Its will be a good idea to implement automation to reduce production time. Also increasing the vessel volume, decreasing no.of batches can also help to more production in estimated time ,ie for example ,better to take 1000kg in 2 or single batch, rather than taking as 10 batches

Para evitar atrasos na produção, é fundamental aproveitar a tecnologia e a automação de forma estratégica. Aqui estão algumas abordagens que podem ser adotadas: . Implementação de Sistemas de Gestão de Produção (MES)Utilização de IoT (Internet das Coisas)Automação de Processos Robóticos (RPA)Inteligência Artificial e Machine Learning.Sistemas de Planejamento de Recursos Empresariais (ERP).Manutenção Preditiva, Impressão 3D,Automação de Armazéns e Logística,Capacitação e Treinamento de Funcionários,Análise de Dados e Relatórios

Delays can be caused by many sort of reasons, and understanding the actual reason will be crucial as a step to avoid it. the best way to analyze would be by the 4M method (manpower, machine, material,methods). Getting to the root of problem, solving or upgrading will eliminate the problem and avoid recurrence of it.

A equipe técnica é o pilar das novas tecnologias. Eles devem interagir inicialmente. Ter dificuldade. Propor soluções, amadurecer ideias. Após isto, são os responsáveis por dar segurança de execução ao time . Com a chegada de toda tecnologia em uma linha de produção, por exemplo, por mais simples que seja a mudança, o desconforto operacional é imediato. Então um time com conhecimento, treinamentos didáticos, e pronto para suportar, faz com que o time caminhe junto com a inovação. Explicar ao time operacional que no início podem ter dificuldades e com o tempo vir mostrando que é normal e corrigir, é o que fortalece o uso de determinada tecnologia. Sendo assim, sem um pilar técnico comprometido, a inovação tem os dias contados para uso.

I believe it’s all about optimizing - process, Human Resources, machines, workforce and everything which is a moving piece around your production process. The goal should be for everything to run like a “Well oiled Machiney” to achieve desired output. But let’s face it - that seldom happens then what we would like to admit. Hence, prepare for the worst and start planning backwards, ensure expectation management is done well across stakeholders. Last but not the least - Never forget Murphys law, “Anything that can go wrong, will go wrong” especially in an environment with so many moving pieces where anything can quickly snowball and become volatile/critical. Hence keep going back to the drawing board. Learning is a journey, not a goal!

You must root cause the delay first. 5 whys, 8D, 3P, DMAIC, whatever tool works for your business. You need a really good understanding of current state before moving on to addressing opportunities for future state. If you have supply chain reliability issues, you must drive home a vendor scorecard with your performance expectations of doing business. If you have a strong Continuous Improvement and Lean culture, you may be able to help the vendor with their own business. Internally it comes down to proper SOP planning & capacity planning, supplemented with CI & Lean to drive out waste. Then look across your shop for automation and technology opportunities to offset any labor attraction or retention issues. Must manage flawlessly to KPIs.

I think continuous improvement through kaizens, small projects are best and sustainable solutions for production delay because this concept are cheaper in cost and also quick.

Perhaps the best place to start .. would consider restating the problem in terms of what the production delays are causing .. Missed orders / Lower Service Levels for example. Tracking the right KPI will make a difference. Now try to identify the reasons we are missing the target KPI through a Loss Tree Analysis. Start prioritising the big opportunities and work through them. It is always a multi-pronged approach .. investing where needed, understanding the demand patterns, ensuring the right resource availability and unlocking productivity.

In many cases, delays or other missed objectives aren't the result of 1 event or problem, but the relationships between several issues. Although it's often convenient (and effective) to highlight tools such as automation as a cure all, don't rely on these methods alone. It pays to look at the whole process, and to include the inputs of those working closest to the situation.

I agree 100%. This comprehensive approach is so vital as we compete for market share. As a a matter of competitive advantage, we owe it to our customers to provide end products that are derived from all available process inputs; not just automation.

- Implement real time data acquisition system with alarms. - Use / review process interlocks to miminise quantum of damages due to breakdowns. - Maintenance management system should capture equipment history n generate Maintenance schedules. - Make small K- groups, quality circles and take Quality improvement projects ( QIPs) to involve all levels,of employees and generate solutions of various types of problems in production line. - Improve communication ( preferably have direct communication leaving behind hierarchy) to bring down time lost in attending to production interruptions.