IMPROVE QUALITY WITH PLANTRUN
Join the many manufacturers tracking defects and rework with PlantRun.
MAXIMISE QUALITY, REDUCE WASTE - GET THE MOST OUT OF YOUR PROCESS
With energy costs rising, getting the most out of your production process is becoming more important than ever before. By tracking quality rates and having targeted data on the issues you have with it, you can start to make changes to reduce the amount of scrapped or reworked products.
MAXIMISING PRODUCT QUALITY THROUGH REAL-TIME DATA
Producing 'first time' high-quality products efficiently is crucial to business success. However, defects and quality issues continue to plague manufacturing, resulting in scrap, rework, recalls, and ultimately increased costs. Implementing a PlantRun real-time data system on the factory floor can help manufacturers improve quality control, reduce defects, and minimise waste.
Real-time data gives visibility into the manufacturing process, allowing issues to be identified rapidly. By leveraging real-time analytics, manufacturers can categorise scrap and rework, track defects, incorporate quality metrics, and continuously improve processes. The result is faster response times, increased productivity, reduced costs, and higher quality products.
CATEGORISE SCRAP AND REWORK IN REAL-TIME
Scrap and rework are some of the biggest sources of waste in manufacturing. When an issue arises and finished products are found to be defective, those products must be reworked or scrapped, incurring additional time and costs. PlantRun tracks the number of poor-quality products and these can be categorised with different types of defects in real-time and you gain valuable data that provides insights into quality issues.
By correlating scrap and rework data, manufacturers can identify systemic issues leading to defects. For example, if a high number of products from a particular workstation are being scrapped for the same reason, it signals a need to troubleshoot that process.
Having granular, real-time scrap data is invaluable for root cause analysis. Digging into the specifics of each quality issue allows corrective and preventive action to be taken to address the source of defects. This real-time feedback also allows for continuous improvement by identifying problem areas quickly.
DEFECT REPORT & TRACKING
One of the most compelling arguments for adopting PlantRun is the rapid return on investment (ROI). Many manufacturers report achieving payback within just 12 months of system deployment. This swift ROI stems from immediate improvements in productivity and the reduction of waste and downtime. As the system identifies and addresses inefficiencies, the gains in production and cost savings quickly offset the initial investment.
Unlike new machinery or additional labor, which may require extended periods to break even, PlantRun starts delivering financial benefits almost immediately.
PlantRun also facilitates the transition from manual, paper-based data collection to a more streamlined and efficient digital system. This digitisation not only enhances data accuracy but also enables faster and more informed decision-making. With real-time access to performance metrics and production data, managers can respond promptly to issues, plan maintenance proactively, and optimise processes continuously. This shift to digital data collection supports a culture of continuous improvement and agility in a manufacturing environment, where timely and accurate information is crucial.
To maximise the impact of real-time defect data, it helps to incorporate it into broader quality management metrics. Common key performance indicators (KPIs) for quality include:
- Scrap Rate = Percentage of products scrapped
- Rework Rate = Percentage of products requiring rework
- Defect Rate = Number of defects identified per unit
- Customer Rejects = Number of customer complaints or returns
Tracking these rates in real-time provides live visibility into quality performance and flags any spikes immediately. PlantRun can calculate SQDC metrics on the fly using all the defect and scrap data being gathered. Production managers can monitor dashboards with live KPIs. Manual data collection and paperwork can be eliminated.
By digging into the categories and specifics driving changes in these metrics, root causes of quality issues are revealed. For example, an uptick in scrap rate may be traced back to a motor component defect coming from a particular supplier. This linkage allows for data-driven corrective actions.
Real-time SQDC measurement aligns objectives around quality. All levels work to minimise scrap, rework, defects, and customer issues. This creates a culture of accountability for defect prevention rather than reaction.
BENEFITS OF REAL-TIME QUALITY DATA
Implementing real-time data analytics delivers significant benefits for manufacturing quality and efficiency:
Faster response time to quality problems since they are identified as soon as they occur, reducing further waste.
Increased productivity and throughput by minimising unplanned downtime, scrap, and rework.
Lower costs through defect prevention and reduced quality-related expenses.
Tighter process control from the continuous flow of data at each production step.
Continuous improvement, as issues are addressed at source rather than just inspected at the end.
Increased customer satisfaction and loyalty through higher and more consistent product quality.
More insightful decision making driven by data rather than hunches.
Real-time quality data analytics provides manufacturers with a powerful advantage in today's highly competitive, quality-focused environment. PlantRun categorises scrap, tracks defects, and monitors critical SQDC metrics in real-time so manufacturers can achieve new levels of quality, efficiency, and competitiveness.
PlantRun enables companies to respond faster to quality issues, tighten process control, drives continuous improvement, and maximise overall quality. By digitising their quality management, they can assure both productivity and perfection. This positions them to better meet rising customer expectations.
PlantRun systems are supplied fully customised and 'ready to use' to an agreed functional design specification. Full training, techncial support, maintenance contracts ensure you get the most from your investment. No annual licensing fees that increase lifetime cost of ownership! Many companies are all ready using PlantRun to improve production performance...
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Why PlantRun?
Real-Time Insights
Watch your operations come alive with real-time data.
Seamless Integration
Connect seamlessly with third-party systems like ERP, MRP, and CMMS.
Master Complexity
PlantRun adapts to your specific demands.
Immediate Action
Swiftly address production hiccups by summoning help right from the interface.
Unmatched Support
Technical support from a team with over 40 years of experience in the field.
Discover the Difference
By making PlantRun a part of your manufacturing journey, you're not only investing in a solution – you're investing in a transformation. We understand budgets and bottom lines, which is why PlantRun often proves its value within a year.
Get Started Today
Are you ready to revolutionise your manufacturing floor? Take the first step by filling out the form below for a no-obligation budget estimate. Unleash the power of PlantRun's Shop Floor Data Collection System and witness the future of manufacturing excellence firsthand!
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