Enhancing OEE Through Real-time Visibility

24 May 2024

In today’s competitive and data-driven landscape, the need for comprehensive visibility across operations has never been greater. This need is becoming more apparent as we transition into Industry 4.0, with its emphasis on connectivity and data-driven decision-making.

Real-time visibility involves collecting, analyzing, and sharing real-time data about the status, location, and condition of goods and materials throughout the supply chain. It offers the ability to swiftly identify inefficiencies and adapt to changing conditions. Key benefits of this technology include:

  1. Enhanced Compliance and Risk Management: Ensures adherence to regulations, reducing risks of defects, errors, and non-compliance.
  2. Operational Efficiency: Monitoring production lines and key performance indicators (KPIs) helps identify and resolve issues quickly, minimizing downtime and waste.
  3. Improved Supply Chain Performance: Identifies bottlenecks and issues, leading to better delivery times and cost reduction.
  4. Optimized Inventory Management: Tracks inventory levels to prevent overstocking and streamline warehouse operations.
  5. Improved Quality Control: Early identification and correction of quality issues enhance customer satisfaction.

Manufacturers can achieve real-time visibility through solutions like Manufacturing Execution Systems (MES), Enterprise Resource Planning (ERP), and IoT platforms. Among these, MES software stands out as the most comprehensive option.

Recognizing the importance of real-time data visibility, AGW features a comprehensive AGW Visual module. It addresses common manufacturing challenges such as production opacity, material shortages, schedule discrepancies, and quality concerns, enabling data-driven decision-making and optimized scheduling.

Key features of AGW Visual include:

  • Production: Real-time KPI visualization, production scheduling, and downtime analysis.
  • Quality Assurance: Digital work instructions, defect reporting, and analysis tools.
  • Labor Management: Access management, operator performance metrics, and compliance tools.
  • Maintenance: Scheduled maintenance activities and real-time equipment monitoring.

AGW Visual significantly enhances plant management capabilities by providing real-time monitoring of production processes, enabling timely responses to issues, and analyzing productivity trends, typically improving OEE by 15% to 25%.

Customer Case Study: Boosting OEE Through Real-Time Visibility With AGW Visual (Tier 1 Supplier. Western Europe)

Business Task: Our customer needed to evaluate facility capacities and enhance Overall Equipment Effectiveness (OEE). They sought a solution for real-time tracking of essential production KPIs for workstation operators on a single screen to improve decision-making and operational efficiency.

Challenge: Integrating real-time data visualization across multiple workstations while ensuring system flexibility to adapt to changing business needs.

Implemented Solution: A customized operator dashboard with AGW Visual, enhancing the AGW workstation framework. This adaptable solution allows easy integration of new features and scalability for additional facilities.

Results: With AGW Visual dashboards, the customer saw up to a 20% increase in OEE at selected stations, improving quality and reducing unplanned downtimes. Timely interventions, facilitated by real-time data, led to more efficient operations and significant improvements in production processes.

In conclusion, real-time visibility is vital for modern manufacturing, driving efficiency, reducing risks, and enhancing competitiveness. MES solutions like AGW Visual provide the necessary digital infrastructure, optimizing production processes and enabling businesses to adapt to evolving market demands.