Measure and communicate performance in real time

All production departments must optimize industrial performance on a daily basis. The continuous improvement process of the processes, the organization or the maintenance is based on the virtuous cycle “measure, analyze, act”.

Even today, the classic solution for measuring performance consists of recording production line stoppages on paper. Beyond its administrative cost, this approach lacks precision regarding the origin, duration and especially the number of stoppages. Distinguishing the relative weight of unrecorded micro-stops from that of sub-stops is therefore very daring.

Moreover, limited use is made of the information collected at the time of production. Graphs illustrating hourly performance are sometimes constructed manually, and the analysis is most often done by copying the data into Excel spreadsheets where several treatments lead to production reports.

These reports are used as a support for daily or weekly production meetings in order to discuss a posteriori the actions that could have been taken…

It seems natural and above all more efficient to act as soon as the information exists. The meetings would be more efficient and would not keep the managers away from their lines as long.

Maintenance must also plan its interventions. The delays in obtaining information can lead to a non-ideal scheduling of maintenance stops. In addition, the low accuracy of measurements often hides the frequency of “1 x 60 minutes or 60 x 1 minute” stops, ignores micro-stops… and can lead to priority problems not being addressed.

In the era of Industry 4.0, why not measure performance continuously and allow operators to turn things around while there is still time?

Synthetis can help you implement this!

Synthetis provides a “Cockpit Performance” software solution that consists of measuring performance in real time in the context of the production plan, taking advantage of available field signals. Relevant information is communicated in real time and promotes rapid action by production players.

“Cockpit Performance” is part of a coherent “Cockpit 4.0” suite of optimization software for the industry, which makes it possible to animate the production plan in real time and to project resource requirements in order to anticipate difficulties as best as possible.

The addition of measured signals improves the quality of the information and reduces the load on the operator. Some inputs can even be enhanced: for example, Cockpit can configure the product markers when a production activity is launched.

It is essential to take advantage of the information available in real time to shorten the decision-making process. “Cockpit Performance” and “Cockpit Production” combine the production plan and performance in real time to assist everyone on a daily basis with relevant information:

– Managers can access line status, performance trends, current and future activities, and end-of-shift projections via the intranet. Relevant information on mobile terminals can also boost staff responsiveness!

– Operators visualize on large screens in the workshop the current status in relation to the objective as well as the projection at the end of the shift.

The information can be analyzed at 360°. With a particularly user-friendly Web interface and screens dedicated to operators, Cockpit can present information in the most appropriate form: dashboard on the line, real-time summary screens in the workshops, batch file for production and quality, analysis tools for maintenance, production, management control, management, etc.

This results in many efficiency gains for everyone!

– Focus of the production manager and team leaders on priorities.

– Motivation of operators to beat the target.

– Decrease in frustration “if I had seen it in time! “.

Analysis of information leads to continuous improvement:

– More efficient maintenance by acting on the main problems.

– Highlighting of production bottlenecks: “show the invisible! “.

– Evaluate organizational choices with figures.

The gain in efficiency of each person and the improvements result in a greater production capacity or a reduction in the number of hours to achieve it.

A profitable opportunity in the short term!