Last updated on Jul 26, 2024

You're facing production delays in plant operations. How can you use technology to prevent them?

Production delays in plant operations can be a significant hurdle, affecting your bottom line and customer satisfaction. However, technology offers a plethora of solutions to mitigate these delays. By understanding and implementing the right tech, you can streamline your processes, enhance efficiency, and keep your operations running smoothly. Let's explore how you can leverage technology to stay ahead of the curve and minimize production downtime.

1 Real-Time Data

Harnessing real-time data is a game-changer for plant operations. By integrating sensors and IoT (Internet of Things) devices, you can monitor production lines continuously, receiving instant alerts on potential issues. This enables you to address problems before they escalate into costly delays. With real-time analytics, you can also make informed decisions quickly, adjusting workflows and resource allocation on the fly to maintain productivity.

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Alice Song

Rapid Prototyping| CNC Machining| Plastic Injection molding| Metal or Plastic parts
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As a manufacturer, sometimes we may meet some production delays. Regarding how to improve and prevent, there are some thoughts: 1.If these things happened, the first step: to find reasons, like technical questions or personnel problems or equipment problem. Find and analyze the problem in a targeted way. 2.After problems solved, next step: review the technical questions, then check and confirm how to avoid in the next time. 3.For some projects that need quickly turn-over, before these orders confirming, team have been confirmed production days. Will confirm again, if it might take longer than expected, then follow-up communication. These are our solutions when faced with production delays.

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Markus Pangerl

...drive your enterprise by contextualized data
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Delays in production do not harm per se... if you know that Murphy is one of your best employees and if it happens systematically, don't plan with 24 h available machine capacity. Detect the root cause which causes most of your delays. Non-bottleneck machines in break-down do not hurt so much as those on the critical path. Debottleneck with principles like drum-buffer-rope. Means: harmonize your production also with lot sizes, focus on bottleareas, focus on safety stocks (buffer) for critical semi-finished goods (i.e. the more unique parts in your production). Consider order networks (rope) or tact harmonization (drum) of your machines (don't use the fastest machine with its max speed if it should cooperate with another slower one).

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Jorge García Rodríguez Operaciones - Mantenimiento - Producción

Gestión de Operaciones Industriales || Mantenimiento || Producción || Abastecimiento || Proyectos || Lean Management
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Los datos obtenidos (que inmediatamente se convertirán en información) en tiempo real es clave, esta información puede ser volcada en gráficas de control (donde previamente se establecen los límites permitidos) y que se activen alarmas ante situaciones no permitidas; esta gran ventaja permite la toma de decisiones de acciones correctivas que posteriormente se convertirán en acciones preventivas al darle el enfoque de mejora continua.

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António Martins

Operations Director # Logistics Director # Supply Chain Director # Consultant # Plant Manager #General Manager (AmeriCold, DHL Supply Chain, Capgemini, Bandague, Logistema. Frans Maas Logistica)
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1. Predictive Maintenance - IoT Sensors. - Machine Learning Algorithms 2. Real-time Monitoring and Control Systems -SCADA Systems -MES (Manufacturing Execution Systems) 3. Advanced Planning and Scheduling (APS) Systems - Optimization Algorithms - Integration with ERP 4. Digital Twin Technology - Simulation and Analysis - Real-time Data Integration 5. Robotic Process Automation (RPA) - Automated Task Execution - Integration with Existing Systems 6. Data Analytics and Business Intelligence (BI) - Dashboard and Reporting - Predictive Analytics Conclusion: Integrating these technologies can help prevent production delays by enabling proactive maintenance, real-time monitoring, optimized scheduling, and informed decision-making.

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Lokendra Singh Tomar

Assistant Manager at Larsen and Toubro Ltd. || Railway Electrification || Production.
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IOT will provide the machine availability and OEE, If anything is below 95℅ OEE than we can start investigation- 1) Any Maintenance activities pending, TPM pillar may help to eliminate this and maintain proper OEE. 2) Manpower issue I. e. Machine being operated below it's capacity. 3) If OEE and Manpower related no issue found we can catch the material flow.

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2 Predictive Maintenance

Predictive maintenance is a proactive approach that uses data analysis and machine learning to anticipate equipment failures before they happen. By analyzing historical operation data and real-time inputs from machinery, algorithms can predict when maintenance is needed. This helps you schedule repairs during non-peak hours, reducing unexpected downtime and extending the lifespan of your equipment.

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Jorge García Rodríguez Operaciones - Mantenimiento - Producción

Gestión de Operaciones Industriales || Mantenimiento || Producción || Abastecimiento || Proyectos || Lean Management
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Lo maravilloso del mantenimiento predictivo es que permite realizar evaluaciones (en muchos casos) sin interrumpir el proceso de producción, al encontrar situaciones anómalas se puede programar la parada con una importante anticipación, de esta manera se reduce el MTBS, MTTR y aumenta el MTBF y Disponibilidad.

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Lokendra Singh Tomar

Assistant Manager at Larsen and Toubro Ltd. || Railway Electrification || Production.
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Predictuve maintenance may help in investigation of machine failure in future, accordingly maintenance activities can planned.

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3 Automation Solutions

Automation solutions can significantly reduce production delays by taking over repetitive and time-consuming tasks. Automated machinery and robotics not only work faster than humans but also with greater precision, reducing the margin for error. Additionally, automation software can optimize scheduling and inventory management, ensuring that your resources are used efficiently and that production lines are never idle due to lack of materials or planning oversights.

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Jorge García Rodríguez Operaciones - Mantenimiento - Producción

Gestión de Operaciones Industriales || Mantenimiento || Producción || Abastecimiento || Proyectos || Lean Management
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Un correcto estudio de tiempos y métodos de trabajo permite eliminar las restricciones o cuellos de botella; dando de esta manera fluidez y rapidez al proceso.

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4 Cloud Computing

Cloud computing offers a flexible and scalable solution to manage your plant operations. By storing data and applications on the cloud, you have access to powerful computational resources on-demand. This means you can quickly scale up your operations during peak times without investing in new hardware. Cloud-based platforms also facilitate better collaboration and information-sharing among your team, leading to more cohesive and responsive production processes.

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Jorge García Rodríguez Operaciones - Mantenimiento - Producción

Gestión de Operaciones Industriales || Mantenimiento || Producción || Abastecimiento || Proyectos || Lean Management
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La ventaja de tener la información en la nube es la conectividad, trazabilidad y visibilidad de la información para que el equipo de trabajo pueda gestionar y dar rápida solución.

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5 Advanced Scheduling

Advanced scheduling systems go beyond traditional planning methods by using complex algorithms to optimize production workflows. These systems take into account various factors such as machine availability, worker shifts, and supply chain logistics to create dynamic schedules that adapt to changing conditions. By maximizing the use of available resources, you can avoid bottlenecks and ensure that each stage of production proceeds without unnecessary delays.

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Markus Pangerl

...drive your enterprise by contextualized data
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By focusing on bottleneck areas (with man-machine interaction), consider to automate subordinated production stages (for unique parts with order networks and stock labeling, for more anonymous parts with order lots based on aggregated requirements)... In mid term planning, consider to solve a distribution problem in time (so group articles with similar modules in their bill of material). Continuously work on complexity and consolidation in your R&D dept. Loop back data from MES to improve in time. Consider alternative sources of supply, even investing in a second machine, or try to build up "combi lines" which are capable to step in in case of shortages. This live-time topic will only work, I admit, if you know your production well.

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Jorge García Rodríguez Operaciones - Mantenimiento - Producción

Gestión de Operaciones Industriales || Mantenimiento || Producción || Abastecimiento || Proyectos || Lean Management
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La programación avanzada permite la programación automática de la producción e integra la cadena de valor dentro de la organización.

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6 Training and Support

Finally, investing in training and support for your staff is crucial when implementing new technologies. Ensuring that your team is knowledgeable about the latest tools and techniques will help them use technology effectively to prevent production delays. Continuous learning opportunities can also empower your staff to identify potential issues and suggest improvements, fostering a culture of innovation that keeps your plant operations at the forefront of efficiency.

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Lokendra Singh Tomar

Assistant Manager at Larsen and Toubro Ltd. || Railway Electrification || Production.
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Proper disciplined training to workers about the machine learning, Capacity utilization to be impart, so team can know the best of best.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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You're facing production delays in plant operations. How can you use technology to prevent them?

1

2

3

4

5

6

7

1 Real-Time Data

2 Predictive Maintenance

3 Automation Solutions

4 Cloud Computing

5 Advanced Scheduling

6 Training and Support

7 Here’s what else to consider

Plant Operations

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You're facing production delays in plant operations. How can you use technology to prevent them?

1

2

3

4

5

6

7

1 Real-Time Data

2 Predictive Maintenance

3 Automation Solutions

4 Cloud Computing

5 Advanced Scheduling

6 Training and Support

7 Here’s what else to consider

Plant Operations

Rate this article

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