Real-time production tracking: A must-have for manufacturers

In today's competitive manufacturing landscape, the ability to track production in real-time has become increasingly critical to success. For manufacturing executives, production managers, and plant managers, investing in a robust production tracker software like Factbird is essential for long-term business success.

This article explores the advantages of adopting manufacturing data analysis software, the particular benefits of real-time output tracking, and how to get started with production tracking.

What is Production Tracking and How Does it Work?

Production tracking, also known as "output tracking" and "production monitoring", is the process of monitoring and managing the production process to ensure efficiency, quality, and timely delivery of products.

Some manufacturers still use manual methods of tracking production, often by using unit counters and collating the production data at the end of shifts or batches. However, by tracking production data in real-time, it is much quicker and easier to identify bottlenecks, optimize workflows, and make data-driven decisions to maximize output. You also reduce the risk of incorrect counts thanks to automation and lessening the risk of data loss.

A production tracking system like Factbird is a solution that analyzes production data, allowing manufacturing executives, managers, technicians, and operators to make informed decisions and adjust their planning and behavior based on data. Factbird is an example of a solution that is more than just software, we also offer plug-and-play edge devices and data integration options to ease the burden of data capture as well.

To get the most out of production tracking solutions, you'll want to integrate it with existing systems, like your ERP and MES, to provide a comprehensive and accurate view of production performance without adding new data silos.

How to Get Started with Production Tracking

Here's how to get started with production tracking.

1) Define Your Goals and Requirements:

Before investing in a production tracking system, it's essential to identify your company's specific needs and objectives. Do you want to improve production efficiency, minimize downtime, reduce waste, or enhance product quality? Clearly defining your goals will help you select the right production tracker software that meets your requirements.

2) Evaluate Production Tracker Software Options:

Research various production tracking systems to understand their features, pricing, and compatibility with your existing systems. Do they charge per line or site or both? Do they offer hardware to help you capture production data from old machines? Do they offer simple pricing for adding multiple PLC tags to the analysis?

We recommend looking for manufacturing tracking software that:

• Offers flexible data capture options
• Has robust production analytics
• Gives you real-time data visualization
• Is flexible thanks to customizable dashboards
• Seamlessy integrates with your current tech stack
• Has flexible pricing.

3) Start small with a Proof of Concept (PoC) trial:

Before committing to a production tracking solution, request a free trial from the software provider to ensure it meets your expectations, offers aclear ROI, and is user-friendly for your team. This is also an excellent opportunity to ask questions, test methods for getting accurate throughput, rework, and scrap counts, evaluate the support provided by the vendor, and build a case for investment in production tracking efforts throughout the organisation.

4) Plan and Implement:

Develop a detailed implementation plan that outlines the timeline, resources required, and milestones for deploying the production tracking system. Involve key stakeholders, such as IT, production managers, and plant managers, to ensure a smooth rollout. Make sure to provide training for end-users to familiarize them with the new system and maximize its adoption.

Would you like more help with rolling out manufacturing software? We have a handy podcast that includes a clear framework for rolling out manufacturing software that you can watch here: The five-step Highway Solution for implementing new manufacturing systems.

If there's one key takeaway from having helped hundreds of companies in implementing smart manufacturing solutions, it's the importance of properly onboarding key personnel in using the new solution. If done right, employee satisfaction will increase drastically along with OEE.

5) Monitor and Optimize:

Once your production tracking system is up and running, continuously monitor its performance and use the insights gained to optimize your production processes. Regularly review your goals and adjust the system's settings as needed to align with your evolving objectives.

The Benefits of Production Tracking

Here are some of the benefits you can expect to gain after implementing a good production tracking solution.

Enhanced Efficiency:

Real-time production tracking helps identify inefficiencies, such as bottlenecks and equipment downtime, enabling quick and effective corrective actions. This results in optimized production processes, reduced waste, and increased throughput.

‍Improved Product Quality:

A production tracking system enables real-time monitoring of product quality parameters, allowing early detection of issues and swift remediation. This not only reduces the risk of product recalls and customer complaints but also enhances your company's reputation for quality.

Better Decision Making:

With real-time production data at your fingertips, you can make well-informed decisions to improve operations, allocate resources, and forecast demand. Data-driven insights empower you to respond proactively to market trends and stay ahead of the competition.‍Cost Savings:

Real-time output tracking allows you to optimize production processes, resulting in reduced waste, minimized downtime, and lower labor costs. These cost savings can be reinvested into the business to drive further growth and innovation.‍

Increased Employee Engagement:

A transparent production tracking system fosters a culture of accountability and continuous improvement. When employees can see the impact of their work in real-time, they are more likely to take ownership of their tasks and contribute to the company's success. SIP Manufacturing is a case in point; they saw reduced employee churn alongside productivity improvements after implementing Factbird.

Production Tracking is a Must-Have

In an ever-evolving manufacturing landscape, staying competitive requires embracing technology and leveraging data-driven insights. Real-time output tracking is no longer a luxury but a necessity for manufacturers looking to stay competitive in a data-driven world.

Production tracking software like Factbird provides the tools needed to track production in manufacturing effectively and efficiently. By adopting such a system, manufacturers, production managers, and plant managers can unlock the full potential of their operations and drive long-term success.

Getting started with production tracking is a strategic investment in your company's future. By choosing the right production tracker software, you can unlock a wealth of benefits, from increased efficiency and product quality to cost savings and enhanced employee engagement.

Don't wait any longer – invest in a robust production tracking system like Factbird to stay competitive in today's fast-paced manufacturing environment.