Manufacturers interface with different challenges. From figuring out overproduction to dealing with excess inventory, idle time, and production defects. All these obstacles can be frustrating. And that is why the concept of lean tools and production monitoring was introduced.
Lean manufacturing is of the school of thought that “companies should only produce the amount that is needed as and when due.”. Because of this, manufacturers don't waste time and energy doing everything. Lean manufacturing is guided by providing value to customers by producing goods that meet their needs.
Continuous improvement in your manufacturing process is found in the steady, incremental change imbibed in your daily activities in the workline. This article sums up all you need to know about lean tools and their effect on real-time production monitoring.
The Role of Lean Manufacturing Tools and Real-Time Production Monitoring
Real-time production monitoring is figuring out how to meet consumers’ demands with minimal resources. But before we dive into all that, what exactly is real-time production monitoring?
RTPM (short for real-time production monitoring) is collecting information from different sources, i.e., machines, equipment, etc., to monitor production processes. The goal is to understand the manufacturing process better, inspect each production line, and evaluate how to better product quality with current resources.
Here’s where lean tools come in. The truth is, there’s no production monitoring without lean time tools. These tools point at the processes consuming more resources without giving the required value and eliminate them. For example, OEE is used to check the time spent on productivity, JIT analyzes production systems, bottleneck analysis is used for structural workflows, etc.
Benefits of Combining Lean Tools and Real-Time Production Monitoring
Saves Cost
Lean tools identify the most valuable product for you to harness on. Manufacturers can save costs by doing this because they are focusing solely on what consumers need now. The time spent on producing an x amount of quantity just to meet all ends would be eliminated. Your top goal would be to produce for current demand. By doing this, you have saved fuel, labor, etc., and there is better allocation of resources.
Improves Product Quality
Another benefit of combining lean tools with real-time production monitoring is it improves your product quality. In instances where “rush hour” occurs in manufacturing because of supply chain bottlenecks and delayed demand, this puts pressure on manufacturers and can affect product quality. Lean tools can help you identify these efficiencies on time and manage the work-in-progress to avoid overproduction or bottlenecks.
Optimized Process
A streamlined process is what makes all the difference in a manufacturing line. With real-time production monitoring, you can set up systems that enable workers to find the tools and materials they need to work with on time. Also, there is a reliable structure for tasks, where each worker knows their designation points and deliverables. With this, there is an efficient flow in production, and it reduces idle time.
Motivates Employees
Employees would be motivated when there is proper monitoring with the right tools. Each worker would be pushed to meet their target because there are tools for monitoring. When the right tools are made available to workers, it reduces frustrations. In fact, workers become more confident in their abilities. Operators would want to follow a standardized process for consistency and ensure quality in terms of production. This leads to more efficiency and commitment from staff.
Customer Satisfaction
With the following systems in place, good product quality is guaranteed, and what is the output? Satisfied Customers. Customers are part of the stakeholders of the company, and if the right structure is in place, the reviews and feedback would definitely be positive. This in return builds connection between your brand and the customers. Why? Because of reliability and consistency in service.
Strategies for driving continuous improvement in real-time production monitoring
Utilize monitoring systems
No systems = No structure. They work side by side. Systems put efficient processes in place for a streamlined workflow. Utilize monitoring tools like sensors to be able to track machine performance. With this you can identify the equipment that is producing more and the one that stifles the manufacturing process. This optimizes the workflow in the factory.
Encourage Employee Involvement
For real-time production monitoring to be effective, your employees need to be involved. Gather all the present data and let them be involved in the decision-making process. Having their insights would foster a sense of belonging where they are aware their commitment is part of the company’s growth. This would further encourage them.
Leverage Data Analytics
Data is the compass you need for the right step to take. This is where lean manufacturing tools come into play. It gives a holistic view of the production process and what to do to make it better. Use tools and devices that interpret this real-time data for effective decision-making.
Train Employees
Upskilling is the code to achieving growth in the manufacturing system. Ensure that your employees are well trained on the systems and tools used in measuring machine performance. Interchange roles to find a worker’s strength and optimize for a smoother process.
Conduct Regular Reviews
Be open to reviews and feedback. Let there be a system that assesses the production process. In the process of doing the same thing, workers can lose touch with the overall goal because they are just driven by the deliverables of the day. Pause and Reassess. Discuss findings and challenges based on data and implement changes on them.
Conclusion
Real-time production monitoring is the catalyst of growth in any manufacturing system. With the aid of lean tools, manufacturers can identify loopholes in production lines and find effective ways to curb them. By following this, workers and operators can save costs, improve product quality, and optimize their production process for better efficiency.
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