Reducing Duplication of Effort with Manufacturing Information Systems

Manufacturing information systems (MIS) have revolutionised the way manufacturing processes are carried out, offering a wide range of benefits, including the reduction of duplication of effort.

In this article, we will explore how MIS reduces duplication of effort and the benefits it offers to manufacturing facilities. We will also look at the part that PlantRun plays in freeing up time of key stakeholders.

Centralisation of Data

Duplication of effort often arises when information is entered into multiple systems or when the same data is entered more than once. This is a common issue in many manufacturing facilities, where data is often entered into various spreadsheets, documents, and software systems.

One of the primary benefits of MIS is the centralisation of data. With MIS, all data is entered into a single system, eliminating the need to enter data into multiple systems. This not only reduces duplication of effort but also helps to ensure that data is accurate and up-to-date.

Example 1: Breakdowns and Rectification

For example, in a manufacturing facility that uses paper-based entry for maintenance requests, a maintenance worker may fill out a paper form with details of the maintenance issue. This paper form is then manually entered into a computer system by a data entry clerk, which can result in errors and delays.

PlantRun's Digital Solution

PlantRun, a manufacturing information system, can eliminate the need for paper-based entry by providing digitised forms and displays. Using the interface on the shop floor, a maintenance worker can complete a digital form with the details of the maintenance issue and submit it directly to PlantRun. This information can be automatically routed to the appropriate personnel or departments, reducing the need for manual data entry and reducing the risk of errors.

Example 2: Production Figures

Another example of duplication of effort in manufacturing is the manual calculation of production figures. In many manufacturing facilities, production managers must manually calculate production figures based on data from various sources, such as machine counters and worker input.

PlantRun's Digital Solution

PlantRun can automate the calculation of production figures by collecting data from various sources and automatically calculating production figures in real-time. This eliminates the need for production managers to manually calculate production figures, reducing the risk of errors and improving efficiency.

Example 3: Paper-Based Lean Boards

A third example of duplication of effort in manufacturing is paper-based lean boards. In many facilities, workers manually check machines or processes and record the results on paper-based boards. These boards are then manually updated and analysed, which can be time-consuming and prone to errors.

PlantRun's Digital Solution

PlantRun can eliminate the need for paper-based lean boards by providing digitised forms for workers to enter the results of their checks. The results are then automatically sent to a centralised database and displayed on large shop floor screens in real-time.

PlantRun’s Lean Boards option allows the traditional paper based colouring exercise to be replaced using tablets and the selection of pass/fail responses. This not only reduces duplication of effort but also enables managers to make quicker and more informed decisions based on real-time data.

Where no shift has been planned, the day is automatically discounted and for each working day the team leaders are presented with a set of questions to determine the overall status for the element.?The resulting data can then be made available on the shop floor through a TV screen, or to the Production Manager through their PC or smart device.

Recording the data also allows comparisons to be made over time to confirm that improvements have been made or to identify previous issues.

Example 4: Start-Up Quality and Health and Safety Checklists

In many manufacturing facilities, start-up quality and health and safety checklists are paper-based. Workers must fill out the checklists manually and submit them to the appropriate personnel. This can result in errors, delays, and duplication of effort.

PlantRun's Digital Solution

PlantRun can eliminate the need for paper-based checklists by providing digitised forms for workers to complete. Using a touchscreen or keypad terminal, workers can complete the checklists and submit them directly to PlantRun. The checklists are automatically routed to the appropriate personnel, reducing the need for manual data entry and reducing the risk of errors.

Example 5: Logging Downtime and Reasons for Downtime

In many manufacturing facilities, downtime and the reasons for downtime are logged manually on paper-based forms. This can result in incomplete or inaccurate data, as well as delays in identifying the root cause of downtime.

PlantRun's Digital Solution

PlantRun can automate the logging of downtime and the reasons for downtime by providing touchscreen or keypad terminals for operators to enter downtime reasons. The data is immediately available in PlantRun, allowing managers to quickly identify the root cause of downtime and take appropriate corrective actions.

Takeaway

In conclusion, manufacturing information systems like PlantRun offer many benefits to manufacturing facilities, including the reduction of duplication of effort. By centralising data, eliminating paper-based entry, and providing digitised forms and displays, PlantRun can reduce errors, improve efficiency, and provide real-time data that enables managers to make quicker and more informed decisions. These benefits not only improve the bottom line of manufacturing facilities but also enhance the overall safety and quality of the manufacturing process.

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