Performance management in production

Improving productivity, enhancing quality, using resources efficiently and productively: with performance management you can optimize your expenditures and revenues.
Performance Management

Data as the basis for greater efficiency

Systematic control and optimization of production processes can be achieved by way of intelligent, data-based performance management, ensuring greater efficiency and productivity. This approach requires that the latest information regarding the status of machines and plants, as well as data on consumption and productivity – both quantitative and qualitative – be recorded and collated as key data.

Generating potential from data

To this end, the essential data must first be recorded from production and saved for ongoing or subsequent analyses – on a local server or in a cloud.

 

These data can then be processed and linked with additional information as required. Depending on the application, an existing SCADA system can be used for this purpose, or an appropriate cloud-based application can read the data from a private, local, or global cloud and present them as key data.

 

Information regarding the consumption of resources, quality, and production volumes can thus be retrieved and evaluated based on current data – but also information that supports maintenance and the efficient utilization of machines or identifies gradual trends. With larger volumes of data, even sporadic or unexpected errors or events can be better investigated – also thanks to modern methods such as machine learning.

Optimize your plant with performance management

All companies would like to optimize their plants, but many have reservations as to whether it is possible to implement systems for the acquisition and evaluation of data using existing resources without impacting plant operation. However, there are now numerous ways to minimize the risks and costs associated with the introduction of a performance management system and enable companies to enter the world of the digital enterprise. In this way, new potential can be exploited.

Monitoring and optimizing the performance of machines and plants

The question:

When I am away from the plant, how can I determine the status of my plant / production line / machine and know whether it is producing the planned quantities?

 

The answer:

Set up an application for the plant in the cloud. This can reveal, for example, that production has dropped to 40 units per minute instead of 50. The cause: incorrect positioning of the material to be processed, due to a malfunctioning vacuum suction cup.

 

The solution for greater efficiency:

The vacuum suction cup is replaced and the productivity of the machine returns to within the optimum range.

Detecting and resolving faults quickly

The question:

How can my service technician in another building always be informed promptly if there is a fault in the plant so that production downtime can be minimized?

 

The answer:

Install a notification and analysis application for the plant. This will send a notification to the service technician’s smartwatch or smartphone, indicating that there has been an unexpected stoppage (e.g., due to a clogged pump).

 

The solution for greater efficiency:

The motor management switches off the pump due to overheating, and the technician can activate pump-cleaning mode. By briefly reversing the direction of rotation, the pump is automatically flushed, after which it functions perfectly again.

Tracking and analyzing trends and key data at any time

The question:

How can I know how efficiently my production process is running this month compared to last month?

 

The answer:

Introduce an analysis and reporting application for the plant. The application will show the overall equipment effectiveness (OEE) for both months.

 

The solution for greater efficiency:

By tracking the overall plant effectiveness (reporting) and applying corresponding optimization measures (maintenance interval, motor replacement, etc.), maintenance planning can be optimized to enhance the utilization of production capacity.

Our solutions for performance management in industry

References

Success with performance management