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Process optimization for older manufacturing plants | MachineMetrics

Eric Hagopian
October 27, 2016


pexels-photo-188710-large.jpegIn a perfect world, manufacturing companies would outfit their facilities with state-of-the-art process and production technology and put it in the hands of skilled operators.

But for many older production plants, things aren’t perfect. In fact, far from it.

Their manufacturing systems are frozen in time reflecting the technology and market environment of the day. Still handcuffed by the inefficiencies of manual adjustments and post-production quality checks, these companies rely heavily on experienced operators and maintenance teams to help them stay competitive.

Poor utilization of resources and inefficient production techniques push their operating costs far above where they need to be in order to compete effectively.  

And in today’s fierce dogfight for customer orders, it’s only going to get tougher.

Fortunately, there’s a solution for those who want to break away from the past so they can start leveraging the benefits offered by modern technology.

And it doesn’t require them to make a major capital outlay in new manufacturing machinery.

Instead, a smaller investment in automated process monitoring and a willingness to replace “old” thinking with modern strategies can produce significant improvements in manufacturing performance.

The first step involves communication - letting every stakeholder in your process optimization environment know you’re stepping up. Like any change in corporate direction, it’s important to ensure your employees and customers are aware of your new intention.   

Then, examine your current operation.

If you’re like many older production plants, your quality control (QC) system limits you to only measuring samples of finished product.

Here’s the problem: while you’re trying to determine whether or not your production run meets specifications, your manufacturing process continues to produce large volumes of product.

You have no way of knowing if the products produced during that run  meet the proper specifications. Get it right, no problem. Miss the mark and the costs can be enormous.

That’s where machine monitoring software – a relatively inexpensive investment, especially when compared to a makeover of your plant room floor – can make all the difference.

Instead of trying to “make do” with aging plant technology that limits manufacturing performance quality, today’s software and sensor technology  levels the playing field.

Imagine being able to perform QC on the fly – online, in real-time – with minimal impact on your production process?

That gives you the ability to immediately identify if a critical process a during production run is not meeting specifications.

Instead of being totally exposed having to wait until you can examine a finished sample, you’re in control. 

In addition to notifying you about whether or not you’re on track for a successful batch, you can also better understand your process so you can improve performance.

As companies become more aware of the process measuring technology available today, the list of those willing to accept subpar manufacturing performance is shrinking.

Instead of feeling trapped by the limitations of an aging plant, take a look at the option of exploring machine monitoring software to see how some innovating thinking can impact your bottom line - without a huge capital investment.  


Ready to move your facilities into the future?

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