WHY DO YOU NEED 20/20 DATA COLLECTION/MONITORING & MANAGEMENT SYSTEM?

Real-time data collection on the shop floor allows managers and executives to make accurete decisions enhancing overall productivity.
(HBS Solutions Ltd. June 2006 By Bora Buyuk)

Production constraints are often difficult to visualize in large complex operations in an assembly line. 20/20 Data System constantly monitors the operations to show and by how much specific operations or assembly stations are constraining your overall production throughput. Performance and line balancing reports rank the bottleneck stations according to their constraint on system output. Realtime visualized analysis provides line supervisors/managers to approach the hourly problems proactively. Traditional manual data collecting systems can only monitor employee/line/ plant efficiency after all the event takes place. Manually collected data on spread sheets can only be entered to a software or excel sheet and can only be analysed the next one or two days. In todays cost competetive production environment management needs online fast, and accurate data collection allowing IE’s, line supervisors or managers to adopt the production environment to the changing constraints.

By capturing and analysing production information right from the plant floor, manufacturers can turn otherwise jumbled data info usable, decision-enhancing intellance. Many manufacturing systems are highly specialized and it takes a certain level of experience to build integration solutions. Companies are applying various types of productivity enhancing management systems like Lean Manufacturing, Total Productive Maintenance or 6 Sigma. All these systems’ main target is to enhance the production efficiency using different systematic approaches. However in common they all need data capturing, measuring and analysis. If you can not measure how can you manage?

No matter what type of manufacturing or process system you are involved with you will be under constant pressure to increase productivity and decrease production costs a primary goal of lean manufacturing. Lean manufacturing is defined as a philosophy that shortens the time line between the customer order and the shipment by eliminating waste (non-value-adding activities). To make any decision on how 'manufacturing process improvements' can be achieved you need access to current information on plant utilisation, performance levels, resource deployment and other strategic production data. You need a Production Monitoring System, a system that can deliver key information where and when it is needed, from the shop-floor to the boardroom, enabling you to make informed and accurate decisions on the best use of your manufacturing assets, decisions which will positively impact your bottom line.
20/20 Data system supports all those management systems simply by answering where actually the specific work order/bundle/piece is, how much direct labour has been done? And how much time has been wasted?

Many job shops and custom factories have dozens or even hundreds of jobs in process at any time through out the shop floor. When a client/engineer from a planning department or a manager asks at what stage the job is in a complex process traditionally most of the times the only way to find out where the job is touring physically the shop floor, looking for the job wasting precious executive time.

Many times if the account departmet asks for how much did that job cost them to produce (All direct labour hours to complete the job) typically a “time sheet” will be created by the engineers and ask each employee to manually complete the sheet progressively through out the day, noting the time and work order number/bundle number of every job he/she is working on. Usually the sheets will end up with filling out ten minutes before shift ends, and the employee is thinking back to what they did eight hours ago causing lack of accuracy. Even the entries are done correctly through out the day when the job is completed someone has to collect all the sheets and manually transpose the handwritten information into a computer program, if it is to be fully utilized causing loss of time and many errors. 20/20 data eliminates secondary data handling by collecting when the operation takes place, gets rid of data errors, provides more information, automaticly interfaces with existing host systems. Provides real time reports i.e. work order, bundle number, employee, operation, plant, line, shift, also answering how much did that employee do, from the shift start to the minute report created with all non value added loss times included.

With real-time data access, managers are able to make well-informed decisions, such as reprioritizing a job or reallocating staffing. Productivity analysis allows users to measure performance and analyse labour costs by employee, operation, customer part number, work order, department, or work center. Based on this data, managers are able to proactively make decisions to improve plant operations. By knowing accurate labour costs, manufacturers are also better able to make informed pricing decisions. Knowledge is power. With 20/20 Data Collection & Management System, control is in your hands.