Identifying Production Blockers and Removing Bottlenecks Using Data 🪄
You don’t have to wait till a machine goes down or you have products you can’t ship before addressing production challenges. Allow us to explain how to go about it a better way (link to our blogpost on Manufacturing Analytics in the comments):
1. Install IoT Sensors for Real-Time Data Collection: Place IoT sensors on machinery and production lines to track performance metrics like temperature, speed, and vibration.
Use real-time monitoring of equipment to quickly identify irregularities that could cause product flaws.
2. Implement Predictive Maintenance Models: Use historical machine performance data to predict breakdowns and schedule maintenance before they occur.
Reduce unexpected downtimes, keeping production running smoothly. 🤖
3. Log and Analyse Machine Performance Data: Track and log every instance of downtime, breakdowns, and performance dips to build a comprehensive history.
Analyse this data to identify recurring patterns or problematic machines that consistently underperform. 📉
4. Utilise Analytics-Based Reporting Tools: Implement reporting tools like Power BI or Tableau to visualise production data.
Use them to identify where bottlenecks are occurring and understand the impact of specific machines or processes on efficiency.
5. Conduct Root Cause Analysis: Use data gathered from sensors and reports to conduct a root cause analysis of bottlenecks or blockers.
Identify whether the issue is due to machine inefficiency, process misalignment, or resource allocation. 🤔
6. Optimise Production Workflows: Adjust workflows, resource allocation, or production schedules to alleviate challenges.
Reallocate tasks or increase machine utilisation where necessary to streamline operations.