PlantIoT Monitor (Rapid Deployment)

To optimize your operation’s performance, one needs to define, relate & analyze the the key performance indicators (KPI’s) that impact your organization.

The challenge: How do you move away from managing the effort to collect the necessary data, and instead turn to analyzing the impact your KPI’s have on your organization? INS will help you accomplish that with solutions that deliver intelligence to any level of your organization – from corporate executive, to management decision maker, even to plant floor personnel.

What are INS’ KPI tracking solutions?
• System Agnostic: Whether you have an ERP system, or a collection of disparate systems, we can bring the relevant data together for your KPI analysis.
• Role-Based: Different views can be provided based on roles, with the ability to restrict visibility to relevant KPI’s.
• Customizable: Regardless of the KPI’s, your view of them is completely customizable in a dashboard to include graphs, trend analysis, indicators, reporting or balance scorecard functionality.

Our KPI Tracking Solutions Can Also Aid In:
• Change Management: Targeted views can aid in change management and adoption of your corporate initiative, showing an individual’s impact to the overall goal.
• Mobile Data Collection: Mobile collection devices can be deployed as part of the solution to reduce or eliminate the lag time in collecting the data necessary for your KPI tracking.
• Replacing Paper Systems: Reducing or eliminating the use, storage and disposal of paper from your manual KPI tracking processes
• Interfacing to Manual Data: Data entry interface can be created to better optimize the time required to capture manual data and eliminate translation errors in the process.

Downtime & OEE

What is OEE?
Put simply, overall equipment effectiveness (OEE) is a measure of what you actually made, in comparison to what you could have made (in theory) over that time frame. The difference between the ideal and actual situation is due to losses.

These losses can be categorized into various metrics that provide you with excellent data to enable you to target that specific area and help you improve. OEE is calculated by measuring performance in the categories of Availability, Performance and Quality, and then multiplying the results. 

Why is OEE Important?
In an ideal environment, all equipment would operate all the time at full capacity producing good quality product. In real life, however, this situation is almost non-existent. Real-time exchange of information between manufacturing and the rest of your company is critical for making business decisions that improve responsiveness, increase productivity, reduce costs and assure regulatory compliance.

How do companies benefit from measuring OEE?
By itself, OEE only provides data about manufacturing processes. But, synchronizing this plant data with enterprise systems creates the groundwork for a real-time enterprise that can adapt to changing demands quickly and resourcefully. The result is manufacturing visibility – a powerful agent for innovation and performance advancement.

Industrial Network Systems has a proven track record synchronizing production and enterprise systems to drive bottom line results across varying industries, from Food/Beverage and CPG, to Industrial and Pharmaceuticals. Companies that track OEE as a metric have found success when combining it with general lean manufacturing programs and also as part of TPM systems. 

Cell Performance Dashboard
Labeling Performance Dashboard
Plant Performance Scoreboard

Benefits of Measuring Downtime & OEE

  • Directly tie production efficiency to fiscal reporting.
  • Reduce investigation time for root cause analysis.
  • Shorten equipment ROI through increased utilization.
  • Decrease costs through waste elimination.
  • Increase customer satisfaction through quality improvement.
  • Pull separate business functions together with a single useful metric.

Standard Operating Procedures

Many plant operators lack clear procedures and must rely heavily on personal experience, which produces inconsistent results. Across the operations team, that inconsistency gets multiplied – especially as your best operators retire and you have new operators with little experience.

Available technologies allow the electronic capturing and sharing of standard operating procedures, simplifying the documentation of processes, transfer of knowledge and driving critical consistency and predictability across your plant. The digitization of manual and automated processes with one tool across your entire facility – provides information as needed for all resources – from plant operators and maintenance teams to field crews and leadership.

Typical Electronic SOP Screen

Benefits of Electronic Standard Operating Procedures

  • Every operator functions as an expert – with interactive, step-by-step instructions
  • Reduced downtime, maintenance and costs across operations
  • Reduced error rate and risk
  • Integrated SCADA and CMMS systems for real-time, condition-based asset management
  • Captured knowledge of best operators before they retire
  • Record and track work processes for compliance