Digital monitoring of manual production
Situation
Purely manual production of unique pieces – no automation to read data from. The only thing measurable was the number of finished pieces per shift; workstation times, inter-operation times and downtimes were invisible.
Solution
Every piece carries a barcode and is tracked from its first entry onto the line all the way to packing. Each workstation has a handheld scanner: one scan on receiving the piece, one on handover. Downtimes – planned and unplanned – are entered by the operator on the spot; quality is verified by visual inspection.
How we read the numbers on this site: The figures in these studies come from people inside those operations – engineers and managers who dug the savings out of their own data. They are not audited or officially approved; companies do not publish numbers like these. That is why we do not name the customers, and why every figure says where it comes from.
Result
The times between scans yield the OEE of every workstation, of the logged-in worker and of the whole line: actual times are compared with the standard times for the given product type, planned downtimes (cleaning, testing) with their own standards, and unplanned downtimes determine availability. On top of that, order fulfilment and a prediction of output to the end of the shift. Deployment required no changes to equipment and no ERP integration.
Honest numbers
The customer did not publish a financial calculation for this deployment. The platform price is not included in any calculation on this site.