Most systems for improving manufacturing productivity start with a detailed analysis of a company's manufacturing processes and operations. The purpose of this is to eliminate wasteful non-value-added processes, systematize valuable processes, automate production and enhance value-added operations.
When it comes to automating processes, implementing a Manufacturing Execution System (MES) may be the best solution. A well-used MES helps to automatically receive data from machines, monitor production, and prevent waste and errors, all done digitally so operators can forget about paperwork.
Let’s take a look at the top five ways MES can be used to improve manufacturing productivity and increase company revenue.
Reduce labor costs
Certain tasks, such as manual assembly, testing and operation of machines, are very time-consuming, especially when manufacturing complex products. Traditional written work instructions or image-only viewing technology may limit new operator training procedures. Additionally, it could slow labor-dependent manufacturing operations.
The operating instructions in the MES will make the operator training process faster, thereby effectively reducing downtime. MES uses advanced software to measure and improve the quality of materials. Productivity and availability will be greatly improved.
Additionally, digital work instructions can reduce labor-dependent assembly operations by reducing the amount of work that must be done manually by operators. MES can guide the manufacturing process throughout the entire planning-scheduling-control-supervision-execution and optimization process.
Prevent breakdowns and waste
Preventing breakdowns and waste in the manufacturing process can greatly impact a company's overall productivity and profitability. It reduces material waste and labor on non-value-added functions.
The MES's screen constantly displays the ongoing process, and just by looking at it, the operator can tell if any assistance is needed. As a result, they can act quickly and make decisions in real time.
While it is important to prevent errors and failures, it is equally necessary to ensure that the entire workforce and resources are fully utilized. MES systems will also uncover quality-related issues and defects, as the cause of low productivity is not always a machine failure, it could be an operator who is not working properly.
Therefore, if there is any threat during quality inspection, MES will identify it immediately. Therefore, the operator can correct it and restore the process to a stable state in the shortest possible time.
Improve communication and teamwork
Communicating with your team is important. Having a designated tool that allows team members to virtually connect and exchange project updates ensures there are no misalignments and misunderstandings on the work at hand
Many MES software involve communication capabilities, allowing manufacturers and project partners to comment on files or receive email notifications. Additionally, it can improve how your team communicates with different departments through email synchronization.
MES systems have built-in communication protocols that allow data to be exchanged in real time. By integrating your MES software with email services such as Outlook or Gmail, you can receive orders or get process updates directly from a single platform.
Simply put, paperless manufacturing processes improve teamwork by speeding up communication between operators and manufacturers on a single platform.
Shorten production time
If production time is shortened, manufacturers can produce more output per shift. Therefore, it ensures more profits for the company every month.
Using MES, production time can be reduced by automating the manufacturing process. MES can track actual work hours and reduce manufacturing cycle times by automatically acquiring data. This helps plan the production process and control its execution.
Additionally, MES reduces the number of micro-stops in the process and reduces the time required for machine changeovers. The software essentially logs downtime that could impact the production process, including errors or micro-stops.
Develop real-time analytics
Detailed real-time analysis helps improve decision-making to determine the manufacturing process. MES is an extensive OEE (Overall Equipment Effectiveness) performance monitoring system with a high degree of traceability, error detection and quality inspection. It collects real-time data and sends notifications for quick response. The system then guides the operator through the production process.
Analysis of historical and current data helps to check the progress of work in the short and long term. Since these documents are digital, there is also a low chance of errors or mistakes. Therefore, manufacturers can avoid double checks.
By using MES to automatically analyze processes and collect data, production can be more easily maintained and controlled. Therefore, it increases the efficiency of the manufacturing process and impacts productivity.