Success is measurable: How data-driven CIP enables production optimization

Faster, higher, further. The demands placed on manufacturing companies are increasing rapidly. To keep pace with this development, continuous improvement processes (CIP) are recommended for the constant optimization of product, process and service quality. Thereby all processes are repeatedly put to the test. CIP is ideally data-driven and based on measurements. The measured values are compared with the target figures and improvement opportunities are identified as a result. An IIoT platform can provide the relevant production KPIs from machines, operational and ERP data. It thus makes a decisive contribution to the success of a CIP in the company.

CIP is a basic principle of quality management and comprises measures to improve the various areas of the company and to sustainably strengthen competitiveness. In order to achieve economic success from it, it is essential to anchor the process as part of the general corporate culture.

CIP teams develop suggestions for improvement

The goal of a CIP is to successively improve the organizational structures and processes in a company with the help of step-by-step optimization. The management level usually initiates the process and the employees actively participate in its implementation. In annual audits, these - usually in teams - develop their own areas of responsibility and the corresponding environment further and further until the first improvements become visible.

In an audit, the ACTUAL state is compared with the TARGET state in a defined area. Problems that cause any difference to the desired state are illuminated. In doing so, they ask themselves questions such as: What is causing the problems? What are the consequences? What are the proposed solutions? All proposals are then evaluated and the possible measures are given a cost-benefit analysis. The results are presented to the decision-makers in the company, and corresponding projects are decided upon and implemented. Measuring the improvements that have occurred concludes this common approach.

IIoT platform provides all relevant production metrics

A continuous improvement process also has to meet some requirements on the technical side. A CIP should always be data-driven, as only such analyses or measurements can precisely map whether target figures are being met in a production line, for example. Hidden OEE potential can also be determined in this way, throughput times recorded and optimization opportunities reliably identified. If appropriate measures for improvement have been taken, a data-based check can be made afterwards to determine whether they were successful.

An IIoT platform such as "toii" of thyssenkrupp Materials IoT GmbH is able to provide the important data basis and thus contribute decisively to the success of a CIP in production companies. It is designed to meet today's requirements for optimally planned, efficient and transparent production.

The IIoT platform transmits all relevant production key figures that can be derived from machine, operational and ERP data. A store floor board filled with data provides the necessary transparency and overview. By visualizing the data, a just-in-time status overview of the producing plants and systems is obtained. For example, employees can see whether the equipment is running at the specified speed and much more. A target/actual comparison is possible at any time. In addition, all employees can immediately see when and where malfunctions occur and react immediately.

Only those who have a precise overview of the status quo can identify bottlenecks, localize sources of error, and uncover and exploit potential for improvement. To do this, for example, OEE key figures, warning messages and evaluations must be displayed simply, flexibly and in line with requirements. The IIoT platform takes care of all this.

Basis for analyses, special applications and automated processes

The IIoT platform "toii" enables data exchange in any direction. To accomplish this, toii is networked with the machines, software systems and subsystems via a variety of protocols. For example, if there is order data in the ERP system that is to be transferred to the machines for changeover purposes, the machines can check the quality with a measuring system and deliver it to the QA system via the IIoT platform.

In addition, toii forms the basis for analyses, special applications and automated processes. Production data can thus be recorded and visualized in real time. This results in effects such as higher productivity, greater efficiency and transparency, as well as leaner processes and lower costs. It also enables companies to increase their level of digitization and set the course for self-optimizing processes.