3 ways disconnected data can be detrimental to a shop floor

In manufacturing, data is everything. It helps to track production levels, identify areas of improvement, and forecast future demand. Without data, it would be very difficult to maintain a high level of quality control. A study done by The Manufacturer states that “almost three quarters (74%) of manufacturing and engineering companies post-pandemic are relying on legacy systems and spreadsheets to get tasks done, believing this inflexible, often out-of-date, disconnected data is sufficient to support corporate decision making.” In a competitive market, those who can make the best use of data will be the ones that succeed.

Financial Loss

When data is disconnected, it can lead to several costly problems on the shop floor resulting in financial loss. When data is siloed and not connected, it leads to inefficiencies and errors. Machine downtime, incorrect settings, and production delays are just a few of the ways that disconnected data can cause financial loss. For example, if production data is not connected to inventory data, then the manufacturing process will be delayed because the necessary components will not be available. This can lead to production bottlenecks and result in lost revenue. In addition, disconnected data can make it difficult to track down quality issues and solve them promptly, leading to increased expenses and frustration. This can lead to costly rework and scrap, as well as customer dissatisfaction. By keeping data connected and accurate, manufacturing companies can avoid these costly mistakes and run their operations more smoothly.

Poor collaboration & communication across departments

In manufacturing, data is critical for collaboration and communication between different departments. This data includes information on everything from production schedules and machine maintenance to inventory levels and shipping schedules. This data is typically stored in siloed systems that are not well-connected, which can lead to problems when different departments need to access, share, and analyze information. Furthermore, disconnected data can also lead to a lack of transparency and accountability, as it is difficult to track where the data came from and how it was used. To avoid these problems, manufacturing facilities need to have a centralized system for managing data. This will help to ensure that everyone has access to the same information and that there is a clear line of communication between different departments. With these efforts, implemented organizations can avoid errors and improve traceability and quality control.

Spreadsheets delay critical decision-making processes

In recent years, manufacturing companies have recognized the importance of using data as a competitive advantage. However, diving further into The Manufacturer’s study the researchers concluded that “28% of senior decision-makers and 27% of managers rely on ‘gut-feel’ all the time to make decisions…but 21% admit to feeling overwhelmed and another 24% to feeling only slightly confident when using data to back decision-making.” These statistics can stem from manufacturers using spreadsheets as opposed to electronic data systems. When companies use spreadsheets there can be many inaccuracies and timing issues. Spreadsheets are difficult to track, manage, and analyze. The difficulty increases in plants with multiple locations, product lines, and data analysts. A tremendous amount of time and labor must be dedicated to sifting through spreadsheets and generating quality reports. Therefore, when a company needs to make an important decision quickly, the timing of receiving the data relies on the speed and efficiency of its employees. When data is connected electronically it leaves room for employees to focus on other tasks to improve the organization and bottom line.

The solution lies in a manufacturing execution system

A well-designed manufacturing execution system (MES) can help overcome these challenges by supplying a centralized platform for managing data. We have created the ultimate comprehensive software solution. MV2 is a powerful MES that helps manufacturing firms get the most out of their existing resources and processes. MV2 constantly collects data from human and machine processes across multiple product lines and warehouse locations. MV2 stores this data and generates accurate, easy-to-read reports that are ready for analysis at any time. Managers can use all these functionalities to build a complete understanding of plant operations and performance.

Are you ready to find the data connection? Contact us to learn more from one of our experienced consultants

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