5 Ways to Enhance Manufacturing process with Real-Time Monitoring

The reason smart manufacturing is being described as the next industrial revolution is that it arises in the wake of technological developments such as increased connectivity and remarkable access to and contextualization of data. Hence, it is no surprise that the smart manufacturing market is assumed to develop to near about 480 billion USD by 2023 according to Statista.

IIoT allows steaming data across various machines in the factory as well as facilities. This provides whole visibility across several operational processes, offering information about the failure of parts, etc. Manufacturers are capable to analyze data trends and recognize inefficiencies in processes, a drop in production or inefficient utilization of materials.

Real-time data allows manufacturers to run simulations to recognize the most effective manufacturing methods. With a concentration on the shop floor, real-time monitoring is proving to be an important aspect. Among all manufacturers in the survey, 81 %  say that real-time monitoring is making huge contributions to their business and 72 %  describe real-time monitoring as crucial for streamlining and making inventory resolution precise.

Enhance Productivity

The fastest-growing manufacturers depend on real-time monitoring to search for new insights into how they can enhance and boost shop floor productivity and stand out in delivering customer requirements at the same time.

The more precise and higher quality the data captured, the quicker manufacturers are attaining lights-out shifts across their plants. Among manufacturers surveyed, 53 % are noticing improved production efficiency as estimated by order-cycle times from real-time monitoring and 47 % are attaining accuracy improvements. All of the manufacturers who have embraced real-time monitoring are giving order statuses to their customers today, further enhancing customer loyalty as well as repurchase rates.

Minimizing Operation Cost

The quality management system is the technology being embraced by many manufacturers this year. The real-time analysis gives the data streams these QMS require to give new insights into minimizing the cost of poor quality, increasing yield rates and achieving higher performance. Among the manufacturer’s survey, 38 % are specifically utilizing real-time monitoring to further increase their quality control. On the other hand, it also provides companies to recognize assets in danger before they are disrupted and cause more serious problems (such as downtime, lost data, and the require to repair or replace equipment).

Downtime is a notable cost for companies and in some situations can lead to loss of data or customers. Replacing equipment in a prompt manner and resolving potential threats are the essential ways to intercept unexpected downtime. A proper automated real-time monitoring tool can be easily incorporated into your IT infrastructure monitoring process and you will soon notice that the advantages outweigh the costs involved.

Minimizing Hard and Soft Fault Errors.

This is regarding the knowledge of online tool conditions and increasing mean time between failure (MTBF) and mean time to repair (MTTR). Real-time monitoring tackle the tool issues and machine level minimizes hard fault errors, including tool breakage, tool presence and workpiece presence. In addition to that, it helps manufacturers to resolve soft faults attributable to machinery acceleration, temperature variation, vibration and force .

Increasing Track-and-Trace Accuracy in Production Plants

Real-time data monitoring allows medical device manufacturers to attain and keep in compliance with the FDA’s 21 CFR Part 821 requirement, additionally to many additional customer-driven audit requests related to track-and-trace. Today, mid-tier medical device manufacturers generally can expect to host between 70 to 90 audits every quarter, further making real-time monitoring important for meeting FDA and customer demands. Better track-and-trace accuracy can also lead to larger real-time logistics synchronization.

Achieving Prominent Sustainability 

Real-time monitoring helps in analyzing energy consumption and finding waste in any production process and hence is important for achieving sustainability goals across all production centers.

Real-time data allows manufacturers to look out for the trouble spots and respond rapidly, reducing potentially greater problems in the future.You can easily recognize trends and actions that cause to the lowered performance of your systems and take the required corrective measures with real-time monitoring. It supports to accelerate the problem resolution process.This will help you to monitor the root cause more efficiently and get to the right solutions quicker.

Real-time monitoring allows the end-to-end visibility across production centers that is enabling medical device manufacturers to excel. The more complex the production process, the more reliance is on real-time data to minimize the incidence of production downtime because of equipment failures.

By implementing the real-time monitoring practices industries can initiate to realize the cost efficiencies, time-to-market benefits, and competitive gains empowered by smart manufacturing.

Technological as well as economic forces are changing the way factories operate. Smart manufacturing that executes using connected and intelligent systems will assist factories to become secure and flexible while improving connectivity that enables collaboration.

Real time monitoring is having a remarkable impact on businesses today and will continue to have positive influence in the future.