Automated Production Reporting in Manufacturing

Saving time and money is a top priority for manufacturers across the industry and automatic data collection does just that. Manually collected data limits your facility’s opportunity to grow and be as efficient as possible.

Reducing machine downtime and producing unbiased and accurate results is vital to the success of every manufacturer. Manually collected data is not efficient because data is entered in the system by a human operator. Sure, your employees are the best in the industry, but human error is inevitable. Automated production reporting will take you one step closer to dominating the industry.

The Dangers of Manually Collected Data

The 3 main disadvantages of manually collected data is that the results are: untimely, inaccurate, and biased. As mentioned above, this is generally due to inevitable human error. You can’t control it- everyone makes mistakes!

Typically, manually collected data is entered into the system at specific times like the end of a shift. Within those times, the health and efficiency of a machine are unknown. When a machine goes down, it can take maintenance hours to respond, which can cost hundreds or thousands of dollars. If the machine is down for longer, it can take insufficient amounts of time to keep jobs moving through the que.

It’s unfortunately very common for inaccurate data to slip through the system. Accidents happen, but they can be extremely costly. Written data can be difficult to read and when it’s misinterpreted and entered into the system incorrectly, it can be difficult to detect and solve.

Manually collected data is also bias because the person entering the data has influence over what and when information is entered. For example, if a plant is understaffed and the operator doesn’t tell the truth about the period of machine down times, the plant will ultimately lose money. These are hidden down times that will go undocumented. Bias is a very expensive problem.

Automated Production Reporting Solves Core Problems

Automation solves the 3 major problems of manual data collection. It is timely, accurate, unbiased, and now affordable. What used to be costly and unreliable, automated production reporting can now be used with Ethernet, on web browsers to easily share data, and is compatible with Structured Query Language (SQL). These advancements allow data collection to be shared within various databases quickly, easily, and affordably.

Choose the Best System

There are two ways to collect data from product machinery: communicate directly with the existing controllers or add a dedicated data collection device to each machine. Whichever option you choose, each system should include a data logger, database, report generator, and real-time updates.

The system you choose will ideally report data including part count, machine states (running, idle, etc.), and error codes. An operation cannot be efficient or effective if this specific data is not accounted for.

The Opportunities are Endless

You’ll more than likely have more data collected then you know what to do with, and that is a great problem to have. The possibilities are endless when an automated production reporting software is in place. Real-time data will open the door for revenue growth by reducing machine downtown and increasing productivity. These systems are accurate, efficient, and affordable- what are you waiting for? Ready to Thrive?