One of the biggest frustrations of manufacturers is the lack of productivity. This is not about just getting things done. It is being able to achieve the set target for each day. Although there are situations beyond human control that can occur, which would affect the production process. But there are ways these obstacles can be avoided ahead. This is where production monitoring comes in.Production monitoring gives managers leverage. Leverage in the form of saving time, resources, and energy by pinpointing issues with the use of data. Production monitoring and tracking uses automation to provide information that managers and workers can then use to move forward. This article covers all that you need to know about production monitoring, from the methods and features to look out for to its importance.
What is production monitoring?
The process of collecting and analyzing data from the manufacturing process to make informed decisions that can aid manufacturers to improve the quality of their output is production monitoring. The essence of production monitoring and tracking is to optimize operations. This means managers and workers can cut down costs, scale in structure, and reduce downtime. This is what boosts growth and innovation in manufacturing companies.
Two Methods Used for Production Monitoring
There are two types of methods used in production monitoring and tracking:
Manual Monitoring
Manual monitoring relies on manual efforts for data collection. Manufacturers use logs or spreadsheets to record data. Inspection of machinery and equipment would go through physical checks, and products are counted and recorded in logbooks. This was prone to errors, inefficiency, and difficulty to scale. This is why the next method had to come in, which is automated monitoring.
Automated Monitoring
Automated monitoring is what most manufacturers use today. It is the use of systems like IoT, machine sensors, and real-time production monitoring tools to track operations. It consists of dashboards and tools that can collect, analyze, and interpret data for you in an accurate manner. These are systems that give insights into workers’ performance, production rate, and inventory level.
Features to look out for in production tracking systems
Data Collection
Data collection is very paramount in finding a production tracking system. The overall aim of production monitoring is being able to use data to make informed decisions. Having software that can accurately collect the data from various equipment and analyze it into information would help workers optimize their operations in terms of speed, efficiency, cost minimization, and product quality.
Real-time analytics
Numbers and manufacturing work hand in hand. Manufacturing is one of the top five industries that require analytics in their processes. The analytics give you the exact number of units in the system and the ones that are ready to be distributed. This is another important feature you should look out for in a product tracking system.
Ease of Use
A production tracking system should be easy to use. The reason why it was created in the first instance is to streamline the process. That is, instead of having to hire an expert to handle the task of data collection and interpretation, which would cost time and money, software can handle that. Not just any software, but one that has accessible features any manufacturer can use at his/her disposal.
Productivity & Task Management
The tool should enhance collaboration amongst teams. A production monitoring tool should handle task management effectively. This is seen in how it monitors and tracks staff efficiency in the form of productivity.
Inventory Tracking
Taking note of stock levels is important in production monitoring and tracking. Another feature that the system should have is an effective inventory tracker. This notifies workers of when material is low and needs to be replenished. This prevents downtime and aids the productivity of workers.
Why do companies need to monitor and track production?
Effective Productivity
The overall aim of production monitoring is effective productivity. As stated earlier, this is not just getting things done. Manufacturers produce with a vision in mind. With every period, either daily, weekly, monthly, or annually, companies have set targets that propel them to meet their overall goals. It's the compounding effect of this monitoring and tracking that helps in achieving this objective. When systems are put in place, managers can review operations and find better ways to be effective in their production.
Improved decision-making
There would be better decision-making in the organization. Why? Because manufacturers are working with streamlined data. The decisions made would not be based on assumption. Qualitative data is readily available for manufacturers so they can use this to make effective decisions.
Cost Reduction
It would help manufacturers cut down unnecessary expenses. They can detect issues earlier. There is also real-time visibility in the equipment productivity. For instance, sensors monitor metrics like temperature and energy consumption to detect unusual issues in heat on time and notify workers. This saves the expense of having to fix it when it breaks down.
Quality Compliance
Production monitoring increases your company standard in terms of quality. It ensures there is consistency in output. And that product meets the industry standards. By doing this, customers become more attuned to your business, and it increases brand awareness.
Competitive Edge
Production monitoring gives manufacturers leverage over their competitors. This is because there is excellence in terms of processes and operations. Also, in tracking data, managers find gaps and solve them, which can then be used as a unique selling proposition. This is what differentiates a brand.
Conclusion
Production monitoring is the future. Leveraging production monitoring and tracking increases efficiency and effectiveness in operations. Manufacturers can use this data to make informed decisions, reduce costs, and enhance customer satisfaction. Before selecting a production monitoring system, look out for certain features before choosing one. This article sums up everything you need to know about production monitoring.
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