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Improving the production process

Knowing how much you sell doesn’t mean knowing how much it costs to manufacture it.

This article aims to demonstrate the importance of analysing overall equipment effectiveness (OEE) and to showcase a system devised by Hexa Ingenieros that minimizes the main issues involved in implementation on the production line.

Nowadays, it’s quite common to come across clients who have fully automated production processes but who lack access to information regarding their manufacturing lines.

At Hexa Ingenieros, it’s our job to show clients the virtues of Industry 4.0. Obtaining feedback on production processes gives companies a major competitive advantage over the rest of the field; the challenge, however, lies in justifying the investment.

Implementation phases:

  1. Consulting.
  2. System integration without halting production.
  3. Data collection and analysis.
  4. Decision-making to solve problems.

During initial client meetings, the question which comes up immediately is: How much is a product batch worth? Most people would think the answer depended on the product’s selling price, but that would be overly simple and not entirely accurate. That’s because within the manufacturing costs the following factors need to be taken into account:

  • Cost of the material used.
  • Production time.
  • Cost of the staff involved in the product’s manufacture.
  • Downtime due to machinery issues.
  • Quality of the finished product.

Being able to reduce manufacturing costs by 15 per cent would directly result in a 15-per-cent increase in sales — a compelling argument for optimizing a production process. Complications arising when implementing the system must also be considered: downtime and problems caused by the existing system’s architecture, for example not having access to the PLC when making changes.

At Hexa Ingenieros, we believe we’ve found the answer to these problems:

  • What if we installed a parallel system to obtain data on production and on downtime and its causes?
  • And what if the information provided by this parallel system could be accessed securely from anywhere via the internet?
  • Finally, what if this system could generate reports in real time and do so from anywhere in the world via a website?

Now, clients would have a web-based tool they could use to ascertain actual production costs.

The next steps would be to analyse the data obtained to determine the costs of downtime, poor quality, low efficiency and the like and then make decisions to continuously improve the production process.

At Hexa Ingenieros, we maximize the cost savings to make sure the investment generates a return. After that, it’s up to the client to decide. And we’re here to help.

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