Improve productivity and resource utilisation with accurate data about the flows of material and semi-finished goods

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Identify problems that reduce productivity

What production issues will you identify?

The most common problems we encounter in production are unplanned stops or delays due to inefficient flows of components to the production line, inefficient flows of WIP between workstations and uneven efficiency of manual processes such as assembly.

How will Indoorway help me solve them?

By continuously monitoring the movement of material handling equipment, it is possible to standardise and continuously monitor the flows into production. By recording the time needed to complete a manual task, we help identify and address root causes of differences in productivity on different stages of the process of between shifts.

How will I benefit?

1. Reduction in unscheduled production downtime resulting from inefficient intralogistics: up to 100%2. Improvement in OEE due to improved labour productivity and standardisation of internal logistics: 5-15 p.p.

What logistics issues will be identified?

The most common intralogistics challenge is standardisation of routes and schedules of tugger trains while ensuring adequate stock levels at the production line and low level of empty rides.

How will Indoorway help me solve them?

Firstly, we analyse how the current process of delivering raw materials to the production line is going, e.g. when the biggest deviations occur and where the bottlenecks are. On this basis, we help to set a standard (routes, frequency of journeys, number of carriages, etc.), which our system then monitors 24/7, providing, among other things, automatic alerts in the event of delays or undesirable deviations.

How will I benefit?

Efficient and standardized intralogistics not only improves OEE, but allows reduction of material handling equipment and even frees up space near production lines that was previously used for transportation or storage.

Improve OEE

How do you measure performance?

We focus on the measurement of losses (Muda) that affect productivity, including loss of transport, waiting, employee movement, over-processing, excess inventory. To do this we analyse the asset location data collected by our system, which we can also combine with information from systems such as ERP or WMS.

How can Indoorway help improve performance?

The data from Indoorway system will indicate the sources and causes of losses, which allows you to prepare a plan for their reduction and constantly monitor the effects of conducted actions. This allows you to better manage change and ensure that corrective actions are permanent.

How will I benefit?

By eliminating waste, you can not only increase productivity to your target, but even raise the bar. For example, eliminating the causes of downtime at one of your work cells can reduce average cycle times, which has a direct impact on OEE by allowing you to increase production volumes with the same resources. The ability to increase the efficiency of current resources, can also result in large savings on potential capital expenditure in new machinery.

How do you measure availability?

Our measurements allow us to identify events that have a negative impact on machine availability, especially those related to changeover times. Very often this is a complex process involving different resources, which makes it not easy to collect the relevant data manually. To deepen the analysis, Indoorway can combine resource movement data with MES data.

How will Indoorway help me improve accessibility?

The data collected by our system is used to plan SMED initiatives and then watch over the correct execution of the changeover process thanks to appropriate setting of indicators and alerts informing about incorrect course of the process, e.g. lack of a worker with appropriate qualifications.

How will I benefit?

Standardisation and constant monitoring of changeover processes significantly helps to increase OEE and thus production volumes. Our experience shows that through standardisation, the average set-up time can be reduced by up to 30%.

Improve use of space and resources

What kind of resources in production do we mean?

Automatically collected information about time spent on different tasks reduces waste (Muda) associated with employee movement (e.g. the need to frequently leave the workstation to fetch a tool or component), whereas the combination of accurate attendance data with a skills matrix, allows to fix the causes of uneven performance between workers e.g. with additional training.

How can I make better use of the space?

In production, any space that does not add value is redundant. Better use of transport means can free up space previously allocated to transport routes or car parks, and improving the efficiency of internal transport can, for example, reduce production buffers and thus free up very valuable space at the production line or nests.

How will I benefit?

More space means that production capacity can be added or the clock can be sped up, because then there is less risk of bottlenecks, for example.

What kind of resources in logistics do we mean?

Indoorway can help reduce empty runs of forklifts and logistics trains, which should result in fleet optimisation.

How can I make better use of the space?

Better use of means of transport can free up space previously allocated to transport routes or car parks, and improving the efficiency of internal transport can, for example, reduce required stock levels and thus free up space occupied by storage bays, part of a warehouse or supermarket.

How will I benefit?

First of all, lower Opex or Capex. The reduction of even one forklift means savings of several thousand EUR/ month in rental, labour costs and additionally in recruitment, as forklift truck operators are often not easy to recruit.