How to Optimize Existing Equipment

Expanding operations amid budget constraints and a tight labor market is challenging. However, achieving higher output without significant investment is possible by optimizing existing resources. 

 

Key areas to focus on include: 

 

To begin, start with a thorough discovery session at the heart of operations. Examine your control system and go through every step of your production process while also evaluating your current quality processes and procedures.  Look for more effective ways to approach tasks, opportunities to automate processes and reallocate human resources, as well as ways to enhance or replace equipment to increase throughput without significant cost. 

 

Also consider if simple changes in raw materials management on the plant floor could speed up production and review the structure of your OT network.

 

By getting a firsthand look at your operations and listening to feedback from operators, quality control, controls technicians and maintenance staff, you can craft a tailored strategy. 

 

Every plant has its own unique characteristics. Instead of a one-size-fits-all solution, explore a range of possibilities with a partner who understands your specific needs. By leveraging advanced simulation and modeling tools, you can demonstrate potential and show return on investment, allowing you to understand how recommendations will impact your productivity long before you make an investment. Once a custom, agile and value-driven path forward is mapped, work with your team to determine an execution approach that keeps budget and downtime tolerances in mind.

 

For many manufacturers, control system and process issues—such as outdated equipment and manual operations—can hinder productivity. While operators may be accustomed to the quirks of your control system and production processes, addressing these inefficiencies is important for overall quality and performance.

A detailed examination of your systems can identify which manual operations could be streamlined through automation, boosting efficiency or freeing your operators for more valuable tasks. Look for hidden causes of downtime and identify aging equipment that's slowing you down. Compare what should be happening versus what is actually happening on the floor.

 

Not all production problems are immediately visible. Hidden inefficiencies can be challenging to uncover. Technical experts can help address these issues—from complex OT networks and security vulnerabilities to quality control challenges and incomplete views of operations.

 

Many plants have evolved from use of isolated systems to requiring reliable connectivity to keep production running. Over the years, this has often resulted in a network that is flat, vulnerable, slow and difficult to scale. Many plants lack OT specialists or have limited OT resources. That’s why it’s crucial to segment the network, virtualize where possible, bolster cybersecurity and optimize wireless networks. Every network has its unique characteristics, so understanding your digital landscape is essential.

 

Robotics offer significant advantages, from advanced vision-based inspection systems to mobile robots for material transport. Robots and/or collaborative robots (cobots) can perform repetitive tasks, allowing human workers to focus on more complex challenges, thus optimizing the production line. 

 

Adopting digital tools can further revolutionize operations. Using AI data-driven decision-making and integrated manufacturing execution systems can unlock new levels of efficiency. Tailoring these solutions to your specific needs helps reduce downtime and prepares your facility for future growth.

 

Collaborating with experts who understand the intricacies of your operations can push productivity beyond current limitations. Embrace an innovation-led strategy to explore and implement solutions that fit your unique challenges, transforming your potential into reality.