lean manufacturing

How Machine Monitoring Works: 6 Steps to Increase Productivity 50%+

May 29, 2024 | Anthony Borges, Director of Marketing, FreePoint Technologies Inc.

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Machine Monitoring is the Process of Connecting Your Machine to the Internet to Collect and Interpret Data.

But have you ever wondered how it works, and what steps are involved? How is it that you cloud-connect machines and processes, and especially older equipment that is not already on your plant network? Cloud-connected shopfloor assets are integral for manufacturing success in Industry 4.0, empowering manufacturers to gather valuable data that can be analyzed, reported on and put into action, with informed decisions that guide continuous improvement initiatives.

In this blog we explore how the process of machine monitoring works, and that when done properly can deliver an instant production increase of 50% or more.

Step #1 | Integration

The first-step in machine monitoring is to connect your machines or processes to the Internet. With FreePoint Technologies’ ShiftWorx solution, our patented black box technology and software algorithm  enables manufacturers to connect shopfloor equipment easily via cellular, Wi-Fi, Bluetooth, and IEEE 802.15.4 standards and protocols.

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Our patented technology cloud-connects new or legacy machines alike, non-invasively. Non-invasive meaning that neither the machine nor its control system needs to be modified for the ShiftWorx solution. A typical machine or process can be cloud-connected in less than one hour. The oldest machine connected with ShiftWorx thus far was a vertical machine built in 1914!

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Patented technology device to easily cloud-connect legacy equipment and enable wireless data transmission; for machines or processes that are not able to be networked to ShiftWorx via direct connection. (OPC-UA).

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Step #2 – Data Transferred and Stored

Once the machine or process is connected to the Internet, data transfer commences. Through the power of the net, data flows seamlessly from each connected shopfloor asset to a secure remote server. By sending the data to the secure server ShiftWorx software is able to give you access to analytics tools, dashboards, report generators, information distribution tools, and more, from any web browser on any device.

Step #3 – Data Displayed

The data from the machines and processes can then be displayed throughout the plant on computers, large shopfloor displays, or mobile phones and tablets.  With ShiftWorx software, pre-loaded KPI dashboard templates are readily available to use, although the manufacturer also has the ability to create fully customized KPI dashboards to display a broad range of information visually.

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Step #4 – Production Increase

By displaying real-time data to your employees about the machines or processes they are working on, you can expect a production increase when the causes of downtime are identified. The real-time data enhances productivity by providing the information that is essential for decision-making and maintenance, and therefore engaging the workforce with this increased transparency. Employees and teams over-all are empowered when a sense of accountability is instilled through performance tracking and clear goal-setting.

Step #5 – Analyze

With the ability to see both real-time data, as well as view historical reporting, plant managers and supervisors can analyze the data to make informed, profitable decisions faster. It empowers all manufacturing stakeholders in fact, with enhanced operational efficiency, quality, workforce engagement, compliance, strategic planning, safety, and ultimately, overall continuous improvement.

Step #6 – Increased Production!

With the ability to analyze machine and process performance, and to make data-driven decisions, production can be expected to increase again-and-again as actions are taken to optimize the shopfloor.  Improved cycle times, accurate quoting, limited downtime and maintenance all help your bottom line.

Through the power of the Internet and FreePoint’s ShiftWorx patented technology manufacturers are enabled with the ability to cloud-connect ANY machine, which is the essential first-step to realizing a 50% or more production increase. Once the machines and processes are connected, the data garnered is truly invaluable towards your continuous improvement goals, which otherwise would not be possible or much less efficient, or more timely and error-prone of a task without accurate shopfloor data for analysis.

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When implementing a shopfloor management solution, choose a technology partner who understands lean and Toyota’s manufacturing methodologies – ShiftWorx software by FreePoint Technologies provides a ‘holistic’ shopfloor management platform that features a fully-modular suite of products including production scheduling, standardized work instructions, digital andon and manufacturing notifications – modules that when applied in whole or in succession afford manufacturers a production optimization solution backed by Toyota Production System (TPS) consulting expertise.

Don’t hesitate to contact us today for a complimentary consultation and demo specific to your Industry or shopfloor requirements!

Learn More About the Full-Suite of ShiftWorx Products!

data

ShiftWorx Software

It all starts with getting your shop floor assets cloud-connected; featuring patented data extraction and visualization technology, ShiftWorx impacts continuous improvement actions instantly with smarter decisions, faster! Book a demo today.

Standardized Work Instructions

Standardized work instructions provide full-accountability in work instructions delivery, whether it’s preventive maintenance, assembly instructions, quality control or more, traceability reduces errors. Book a demo to learn more!

Digital Andon System

Digital Andon improves shop floor communication and production uptime by ensuring operational or quality issues are addressed quickly! Wireless and easy to integrate – expedite the resolution of production and quality problems today.

Production Scheduling Software

Spreadsheet or paper-based job schedules are difficult to manage, maintain, distribute, and access, which is costing you money. Maximize operational throughput with production scheduling software.