We did not have any solution. All data were collected manually. The team relied on operators and supervisors writing down events, stops, and performance information, which made it difficult to see what was happening in real time. We had no information about the time wasted on the shop floor or the production line. When we counted everything together, we were losing 200–300 minutes per day. Without accurate data we couldn’t analyse our processes or understand where the issues came from. We wanted to increase OEE, reduce waste, and avoid human mistakes during the production process.

We overreached our targets. The shift from manual processes to automated data collection had an immediate effect. Our general OEE target was +2%, and the result has doubled, and it is inculde the TPM metric as well. Waste dropped by a large margin. Operators could rely on system validation, reducing errors related to materials and setups. “BOM validation became easier and operators aren’t making mistakes where the system was implemented. We now have full visibility over the shop floor. The availability of real-time data also changed how decisions are made. Supervisors can now address issues at the moment they appear, rather than after the fact. Review collected by and hosted on G2.com.