Consumer goods (FMCG)

Improve production efficiency and resource utilisation with accurate data on material and semi-finished product flows.

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Identify problems that reduce productivity

Production
Logistics
What production issues will you identify?

Common problems we encounter in the fast moving consumer goods industry are unplanned stops or production delays due to inefficient organisation of flows to the production line from the warehouse.

How will Indoorway help me solve them?

By constantly monitoring the movements of forklifts and order pickers, it is possible to standardise and constantly monitor the flows into production.

How will I benefit?

Reduction of unplanned production downtime: up to 100%

What logistics issues will be identified?

Logistics directors do not currently have good indicators to diagnose the performance of internal logistics and analyse the causes of problems such as late deliveries or the delivery of too few or the wrong components to the production line. Day-to-day management is not easy either, especially with the high volume of raw materials, variable production volumes and the push model.

How will Indoorway help me solve them?

Our system automatically monitors and analyzes process such as order picking and milk runs, so you can immediately see when and where problems occur. Our analyses then help to standardise the process in terms of schedule, resources used and the needs coming from production. The system monitors the process 24/7 and also provides live feedback on unwanted events or deviations from the developed standard.

How will I benefit?

Efficient and standardised internal transport not only improves OEE, but also enables a reduction in the number of resources involved in internal logistics and precise and predictable production planning.

Improve OEE

Performance
Availability
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 the 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 make sure that corrective actions are permanent.

How will I benefit?

By eliminating losses, it is possible not only to increase productivity to its target, but even to raise the bar. For example, identifying and fixing the causes of lost motion for machine operators can reduce average cycle times. Being able to increase the productivity of current resources, can also save a lot of money that would have been spent on investing in new machinery.

How do you measure availability?

Our measurements allow us to identify events and behaviours that negatively impact 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?

Data collected by our system is used to plan SMED initiatives, standardisation and then watching over the correct execution of the changeover process thanks to appropriate setting of indicators and alerts informing in advance about potential problems (e.g. lack of an employee with appropriate qualifications) or prolonging the changeover process.

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

Production
Logistics
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 can free up space previously allocated to transport routes or car parks, and improving the efficiency of internal transport can reduce production buffers and thus free up very valuable space at the production line or machines.

How will I benefit?

1. Increasing staff presence at machines should have a direct impact on OEE, up to 10 p.p.
2. The space freed up may allow for an extension of the area used for production or a more optimal arrangement of machines, without investing in the expansion of production space.

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 per month in rental costs (much more if it's a purchase) and drivers' work. In addition, there are recruitment costs, especially since forklift operators are often not easy to recruit, and their rotation in regions with many production plants and warehouses is usually high.