In the face of manpower cutbacks and a greater need to keep an eye on the bottom line, how do manufacturers improve flexibility and profitability? By embracing real-time performance management—at least that's the consensus at Plant Engineering Live, an online portal that provides strategic manufacturing knowledge to help the plant manager operate efficiently, effectively and safely.



And if you happen to be a factory floor manager, then a real-time data collection system that provides job tracking and factory floor control might be just the ticket to a roll-with-the-punches attitude and higher profits. In the face of a global recession, both of these benefits are welcome side effects on every shop floor.

The article went on to point out, “This [necessity of keeping tabs on their personnel and profits] is intensifying the need for companies to make key performance indicators (KPIs) visible across all levels of the operation to help provide that processes are operating correctly and assets are being effectively utilized.”

When it comes to the factory floor, an Advanced Planning and Scheduling (APS) and finite scheduling system provides the underlying data for metrics and key performance indicators such as labor efficiency, bottleneck analysis, operation time standard analysis and OEE. Through a PC-based system that is completely interfaced with most ERP and MRP systems, it also:

1. Visually improves the sequencing of production (and raw materials)

2. Is a Time and Attendance System with online supervisor approval and rules to match a manufacturer's way of paying its employees

3. Can monitor machine cycle counts with a customizable human machine interface (HMI) that provides a real-time view of the factory floor for more accurate and timely asset analysis

4. Provides visible feedback and floor-level management

“While many companies have enormous potential for improving plant performance, they're challenged with collecting, organizing and analyzing the data needed to identify areas for improvement. By applying performance management solutions, organizations can simplify the information-gathering process, while providing the role-based visibility and in-depth analysis needed to make intelligent business decisions,” the article continues.

Thanks to its touchscreen capabilities, a real-time data collection system simplifies factory floor managers' jobs with better scheduling, WIP tracking, data collection and time and attendance labor management. In sum, it provides them with a visual factory that is easy to see and, therefore, easy to control so that they can focus their attention on their bottom lines.

The article concluded, “Those companies that capitalize on these technologies will be the ones best positioned to reap continuous performance improvements and gain a substantial competitive advantage now and into the future.”

Indeed, a shop floor management system not only allows manufacturers to take their manufacturing to new levels and improve the efficiency on their factory floors, it also enables them to compete on speed rather than cost. In addition, it delivers real-time, continuous improvement for greater profitability and faster delivery to customers.

In tangible metrics, implementation of a real-time factory floor data collection system can result in:

• 25% increase in productivity

• 50% reduction in inventory

• 50% reduction in work-in process

• 80% improvement in on-time delivery performance