MANUFACTURING INTELLIGENCE: POWERED BY INDUSTRY 4.0

A large majority of manufacturers remain dependent on inefficient data collection systems. Many continue to rely on data manually captured from their operations by shop floor personnel. This information is usually input into systems and then later evaluated. Part of the reason that this problem persists is that it is difficult to autonomously capture data from manufacturing equipment and operations. This article explains why machine connectivity is such a challenge and how...

One of the most common questions we get from manufacturers: What data can I collect from my equipment and operations using MachineMetrics? The answer will rely on the make and model of the equipment and control in question. One of the hallmarks of our platform is the depth and breadth of machine connectivity. Not only do we connect to any make, model, and age of discrete manufacturing equipment (turning, milling, stamping, robots, paint lines, belt sanders, manual welders,...

In recent years, many manufacturers have reconsidered their supply chain strategies and looked to reshore or nearshore critical segments. This trend is driven by various factors, including rising labor costs, ongoing disruptions in far-flung supply chains, inflation, new and stricter ESG initiatives, and more. As countries vie to gain a competitive advantage in these new strategies, Mexico has emerged as a particularly appealing option for manufacturers looking to optimize...

Every manufacturer has been there: Orders are out of control, and demand is sky-high. Overtime has become the norm, and everyone is wondering how to meet demand without increasing lead time and creating quality problems. All too often, when this scenario arises, the answer is presented in terms of more labor or equipment. Those are certainly the most common answers, but also the most expensive. Do you understand your equipment and processes well enough to know whether adding...

Many complex elements are needed to run a modern manufacturing operation. Equipment, raw materials, operators, and supply chain professionals work together to ensure production is on time and made to specifications. Production scheduling is also a critical part of the process, acting as a roadmap for production. But planning out production in an accurate and effective manner has historically been a challenge. There are many variables at play, not only the internal...

The need for knowledge transfer has always existed, from verbal stories handed down over generations to handwritten notes passed from an existing employee to a new one. The same need has always existed for manufacturers to ensure product consistency and equipment operation. But today, it’s even more critical. As other employment opportunities have grown, manufacturing companies have found themselves without enough skilled workers. In many cases, more “head” knowledge is lost...

Change is inevitable. But the rapid pace of changes brought on by severe disruption has altered the way companies do business. This has led to significant shifts in the global supply chain that affect manufacturers from placing raw material orders all the way to the production floor. After an initial rally in mid-2020, supplier lead times began to increase again at the beginning of January 2021. By Q3 of 2021, lead times had grown 2.5% higher than during the pandemic. The...

Manufacturing is an expensive undertaking. Manufacturers must delicately balance materials, labor, and overhead costs against sales goals to maximize profits and hit their targets. Quotes help navigate this complex equation, ensuring customers quickly have an idea of the cost of a given job. This can be a tricky process as manufacturers must have a strong record of their overhead and operating expenses across all the different parts they offer, as well as the ability to...

Organizational change can be organic and incremental. But it can also be rapid and nerve-wracking, triggered by technology advancements, disruption, or both. Over the last decade, manufacturing has often been on the losing end of change when finding and retaining employees. Faced with decades of cultural bias that negatively defined manufacturing to those entering the workforce, producers were already disadvantaged. The promises of an academic degree, high-tech employment...

Cloud computing and software as a service (SaaS) are increasingly popular in the manufacturing industry, with many companies taking advantage of their benefits to optimize processes and improve efficiency. Despite the advantages that cloud computing and SaaS bring to the table, many executives and IT decision-makers are hesitant to embrace them due to a variety of concerns including security and cost. There is also a fear that the cloud represents a new way of managing data...