Five ways consumable, democratized data improves factory operations

Manufacturers are increasingly turning to smart manufacturing principles, hoping to turn the shop floor into highly efficient, data-driven operations humming with synchronized precision. Unfortunately, line-of-business managers, crew leaders, and shift supervisors—the shop floor heroes—often lack easy access to the ERP system and the relevant data needed to keep production on track.

Deskless workers play a vital role in operational efficiency and countless critical decisions are made on the shop floor every Shift, that’s why fast-moving production lines require fast decisions and expedient action.

Empowering front-line users, putting data in the hands of every decision-maker in the organization, even those who aren’t advanced data analysts, so they can get immediate answers to design questions or specifications on a custom work order.

Access to information keeps production lines moving as planned, with minimal interruptions because of questions, disconnects between departments, or stockouts, and artificial intelligence (AI) and machine learning (ML) have moved into the mainstream. Routine processes can be automated, streamlining the need for human interaction. Only anomalies or exceptions need to be routed to supervisors for individual attention and one data-driven digital thread will connect every stage in shop floor operations.

Here are five examples of how democratized data helps boost productivity:

1. Accurate scheduling. Synchronizing production runs to fulfill customer orders depends on accurate account data as well as sales, delivery promises, inventory of raw materials, and machine capacity. Working with co-manufacturers or subcontractors also requires access to information. Collaboration portals can help share information while protecting security.

2. Strategic scheduling of the workforce. With data insights, managers can track and understand performance of shifts and crews, identifying essential staffing requirements and tracking expenses. With the acute labor shortage manufacturers face today, careful scheduling of right-skilled workers is especially important.

3. Workflows. Keeping operations running smoothly with no gaps, delays, or roadblocks requires coordination among teams and sharing data on job status, equipment performance, and scheduling. Reporting can help identify trends and analyze variables, allowing managers to delve deeper into influencing factors that can be improved. Decisions can be made, changes executed, results monitored, and further refinements made. Continuous improvement can be part of the system and standardized workflows. 

4. Waste reduction. As manufacturers strive to be more sustainable, they place a high priority on reducing waste, including energy, water, and raw resources. Reducing scrap is essential. By improving consistency and quality control, fewer units will need to be scrapped or reworked. Access to data will help crews verify proper machine settings, consult knowledge banks for typical resolutions of issues, and verify proper specifications and variables.   

5. Compliance and quality control. Managers need to track, monitor, and evaluate quality standards, with a continuous feedback loop in place. As new products are introduced, specifications need to be easily updated and accessible to relevant teams. Regulation compliance, too, is critical in many industries and demands accurate reporting. Democratized access to data helps keep the details in view when and where they are needed most.

Manufacturers considering deploying their first ERP solution or upgrading a legacy solution, often compare various vendors and the functionality of their solutions. A factor that can be overlooked is the usability of the system and how accessible the data is to workers throughout the organizations. Some vendors offer ERP solutions that are cumbersome and difficult to use, meaning many of the features will simply not be used.

In contrast, some solutions offer built-in industry-specific functionality and make usability a top priority. Easy access to data is essential and a characteristic to look for in a smart ERP selection.

To find out more about how NLS can help you get there faster, click here!