The Future of Manufacturing: The Intelligent CEO Control Centre
Industry 4.0 is an opportunity for manufacturers to reinvent their operations by using digital technologies to automate processes (as discussed in part 1) and gain actionable insights. However, getting the right data that can suggest ways to improve operational efficiency and identify opportunities for growth can be akin to finding a needle in a haystack, as data is being constantly generated by machines that are becoming increasingly connected.
Manufacturers can overcome this challenge by providing their CEO a single pane of glass that gives a snapshot of all their operations. OMRON’s Future CEO Cockpit, for instance, unifies data generated by connected devices in factories before leveraging third-party software solutions to analyse and present them in easy-to-understand formats such as graphs, pie charts or speedometer. This enables the CEO to quickly identify bottlenecks and take remedial actions. Here’s more on how it can benefit manufacturers:
Determining the health status of your entire operations in one glance
Since the latest Omron factory automation systems and components are now connected and smart, they enable real-time monitoring and collection of data. To distil the information and extract actionable insights, the data is fed into third-party software solutions like Arcstone’s advanced manufacturing execution system to build a data-driven production ecosystem.
With this dashboard, CEOs are able to quickly determine the performance of their global operations. By having information on a factory’s availability and output levels, overall equipment effectiveness (OEE), the number of alarms it experienced recently, and the average time it takes to recover, CEOs will be able to better anticipate disruptions to operations and take the appropriate measures to prevent such interruptions.
Diagnosis made easy
With the aim of enabling factory-wide optimisation, the Intelligent Dashboard by Fujitsu here allows CEOs to easily assess the performance of every factory by providing granular information such as the efficiency level of equipments, yield rates, energy consumed and availability level of all the manufacturing lines. With these information, CEOs can take the necessary actions to optimise energy consumption and adjust workflows to eliminate inefficiencies; both of which could help lower overall operating costs.
The dashboard also presents the production lines visually, making it easier for CEOs to identify which parts of the line are disrupted. In this case, we can see that some parts of Line A are facing issues related to materials and machines. By quickly resolving them, the manufacturer can minimise the time and cost lost due to bottlenecks.
Prevention is better than cure
CEOs faced with the same scenario in the previous slide can use the dashboard to drill down even further to identify which equipment is holding up the production line. In this case, the bottleneck in Line A is due to issues faced by the printer and two multi-purposers.
The dashboard also shows which order the production line was fulfilling before it was disrupted, details of disruptions the line faced recently (e.g. no paper, printing error), its workload and output levels per hour.
With these information, manufacturers can shift from reactive to predictive maintenance as they can determine which machines require servicing before they break down. This not only reduces the risk of disruption to the factory’s operations, but also saves the cost of regular maintenance. At the same time, these information can enable just-in-time inventory management, which reduces the space and cost needed to store excess inventory.
Timely identification of underperforming countries
The intelligent dashboard allows manufacturers to compare how its operations in various countries fared against each other. Here, we can see that even though factories in Holland collectively produced more good end products than those in China, the former disposed more finished goods. This could be because factories in China made more manual corrections to the products before they reached the final manufacturing stage. With such as dashboard, CEOs can effectively identify which countries are underperforming and the general areas they require help in.
Feeling the pulse of different regions
Suitable for manufacturers with global operations, this dashboard enables CEOs to compare their operations – in terms of equipment, energy and management efficiency – by regions too.
Besides that, the dashboard displays relevant news that could affect the manufacturers’ business, such as the enactment of environmental legislations in certain countries. This will help CEOs better prioritise the actions needed to be taken to improve their business.