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User Spotlight

"PlantRun has revolutionised how we monitor OEE..”
Stuart Pearce
Operations Manager
Presspart Manufacturing
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The efficiency of machine operators can often be the most significant factor in improving manufacturing performance. Being able to track and analyse operator efficiency is crucial to this improvement.

PlantRun offers cost effective retro-fit conveyor monitoring systems to measure throughput, speed, run-time, down-time and more.

Throughput of items or weight, speed and runtime only requires connection to a suitable sensor, which may already be pre-fitted to the conveyor. With the addition of an operator interface further information can be captured such as specific product or load type, batch ID, reasons for downtime, scrap etc.

Pre-start, pre-use or pre-production checks that require completion before operating a machine or asset can now be automated using PlantRun. Checking the asset and area for hazards, correct set up, provision of PPE etc can minimise the risks to your staff and ensure due diligence.

Checklists can be displayed on a PC, touch screen or tablet at the asset (or at any convenient location) when the operator logs on. The operation of the asset can be disabled, until the checklist has been completed. 

The completed checklist is stored directly to digital format allowing easy retrieval and analysis and reporting.
  • Checklists questions and answers can be randomised if required.
  • Allows assets to be secured by password and privilege
  • Stop workers without the correct training operating machines or equipment
  • Paperless work instructions and procedures can also be displayed
  • Access to assets can be controlled centrally
  • Assets that are unfit for use can be disabled remotely
To find out more contact us for further information
A manufacturing traceability system is enabling 3M to track critical input materials and components used in the production of respirators and particulate filters.

When manufacturing respirators a number of materials are fed into the process. To ensure compliance with the relevant standards it is necessary to have a process where input material batch numbers can be linked with output product.

The system replaces manual collection of input material batch numbers on to paper records. The requirement for paperless data capture was highlighted during the introduction of SAP on site.

manufacturing traceabilityIntermec CK3R mobile computers provide a convenient operator interface with touch screen for simple interaction allowing users to scan barcodes for the following:
  • Station ID
  • Operator ID (from their employee card)
  • Stock number (from the raw material ID ticket)
  • Batch number (from the raw material ID ticket)
Data is recorded to database making it available in virtual real time across the organisation on PC’s, tablets, smart phones, large screen displays in production and meeting areas etc.

As well as inputting data from barcodes, data is also captured automatically from PLC’s, including critical machine operations, pallet number, product count and product ID etc. Links to Zebra GK420 label printers enable printing of labels for pallets and boxes.

The system has been developed to work across all production areas on site including an area that is validated to FDA 21CFR Part 11 standard for electronic records and electronic signatures.

3M is a multi national corporation with global sales of over $31 billion (2017)

Having easy access to accurate manufacturing key performance indicators is vital to effective management and production efficiency.  Manufacturing KPI reporting is a major benefit of a PlantRun real-time manufacturing information system. The KPI data that is collected and stored by PlantRun can generate management reports or be displayed on manufacturing dashboards.

Reducing equipment or machine down time has an instant beneficial effect on manufacturing operational availability and output. However, without accurate information on the true amount and causes of unplanned downtime it can be difficult to identify how it can be reduced.

OEE highlights the “major losses” in the manufacturing process for focused improvement. It can then be used to measure the effect of efforts or initiatives introduced to reduce the major losses and thereby tap “hidden capacity”.

PlantRun systems continuously collect data from all monitored machines.  This information is then presented on a PC display as a 'shop floor overview', which provides an instant picture of the condition of every machine. Similarly large format overhead displays can provide relevant KPI information in production areas.

  • Minimise extended breaks, late starts, early finishes
  • Reduce overtime, shifts, manning levels
  • Increase competition and motivation

Measuring and improving operator efficiency of machines and equipment on the shopfloor can have a dramatic effect on manufacturing productivity and output.

Few manufacturers would admit to manufacturing unprofitable products even if they knew it. However, if you are manufacturing a range of products chances are that one or more could be unprofitable, unless you can accurately quantify the on costs of making each product line.

A manufacturing bottleneck is a constraint or choke point that limits production output.  Many manufacturing operations suffer from bottlenecks caused by one or more machines and the bottleneck may change depending upon the actual product being manufactured. Identifying and managing manufacturing bottlenecks can have a major impact on output and profits.

Are your machines stopped when they should be running?

Save 15 to 30 minutes per shift per operator? That’s what 41% of current users report*

Poor time keeping, operators starting late, taking extra time during breaks, finishing early and taking longer to restart a machine than they should is a typical scenario in many manufacturing companies.

Visual factory management is as it suggests the use of visual cues or aids to enable improved management of factories and manufacturing production areas.

PlantRun enables visual factory management in several ways including;

PlantRun is a real-time asset utilisation system and provides sophisticated collection, reporting and analysis of downtime – which is a major cause of lost manufacturing production.

engineer buttonPlantRun can provide highly accurate maintenance KPI’s in real-time for improved maintenance effectiveness or performance.

Quick Changeover, also referred to as Setup Reduction aims to minimise non-value added activities during production changeover and the setup processes, enabling faster, more efficient change from one product to another.

The manufacturing cost per unit or production cost per unit is often a crucial metric and can vary greatly from one production run to another depending upon the input cost variables.  An example would be when extra staffing is used to ensure rapid throughput at times of high demand.

Since it’s original development in Japan in the 1970’s OEE or Overall Equipment Effectiveness has become a widely used metric for measuring manufacturing efficiency.  OEE is the main tool of the Total Productive Maintenance improvement program and is used to reduce or eliminate the “Six Big Losses” that limit production.

PlantRun systems automate manufacturing OEE data collection, reporting and analysis eliminating the problems and costs associated with collecting and processing OEE data manually.

Short Interval Control (SIC) is a powerful method for improving production efficiency by focusing attention on major losses and forecasting risks over short time spans.

Accurate production line monitoring enables you to maximise efficiency, capacity, improve management as well as inform and motivate your staff.

SmartView gives you mobile business intelligence allowing you to remotely access your manufacturing operational kpi data directly from any mobile device.

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Acting as a mobile dashboard SmartView displays real time metrics directly from your PlantRun system allowing you to view the critical information you need for the smooth running of your business, whenever, wherever.

Increase Output, Reduce Downtime, Improve Quality, Cut Costs, Maximise Profits - Under One Year Payback Typical

In complex and competitive global markets today, is more vital than ever to maximise the effective use of manufacturing equipment. Improving shopfloor management and operational visibility is now a requirement for leading manufacturers and the status quo no longer justifiable.

Increase Output, Reduce Downtime, Improve Quality, Cut Costs, Maximise Profits - Under One Year Payback Typical

Accurate real time manufacturing data is crucial to maximising production efficiency, improving shopfloor management and manufacturing cost reduction.

PlantRun is not a planning and scheduling system but aids production planning and scheduling as each new production run or batch is identified by a unique user defined batch reference. The information for that run or batch, including start and end times and all relevant monitored parameters, can then be stored in the system database against that unique batch reference.

PlantRun has specialised facilities that enable manufacturing knowledge management through its use as a central knowledge base and as a manufacturing expert system.

Problem, breakdown or stoppage? Call for assistance at the push of a button.

Andon is a Japanese term for a system used in manufacturing to alert when there is a production problem in order to minimise any effect on output.

With PlantRun this alert can be made by pressing a button on the operator interface at the asset or may be activated automatically when a system alarm is triggered.

Get accurate live production counting from all your manufacturing assets - machines, lines, work cells, and manual operations - with PlantRun.

Reducing machine downtime has an instant beneficial effect on manufacturing production efficiency and output. However, without accurate information on the real amount and the causes of downtime it can sometimes be a difficult to see how machine downtime can be reduced.

PlantRun systems act as a manufacturing notification system by distributing information whenever and wherever it is needed, based on events and alarms, to enable smoother running of your production operations.

The primary aim is to provide faster response to and minimise production issues.

Real time monitoring of machine speeds provides two main benefits for improved efficiency.

Firstly, it is possible to accurately monitor speeds against target levels for each machine and alert when they are performing out of range.  In particular small variations in machine speed often go unnoticed by operators whereas a monitoring system can immediately alert the need for corrective action to be taken.

Data capture using barcode systems offers enormous benefits for manufacturers. Data capture is faster, more accurate and mistakes are minimized.

With a barcoding system you can easily obtain information that would be difficult or impossible to obtain otherwise. Faster access to information enables better management, better decision-making allowing you to gain advantages over the competition.

PlantRun is a highly effective machine monitoring system for manufacturing production data collection reporting and analysis that can capture any other required operating parameters.

Cost effective, expandable and futureproof

Having accurate information at production level is crucial to drive manufacturing efficiency and lean and continuous improvement initiatives. PlantRun provides a highly cost effective way of real-time production monitoring to enable you to;KPI displays
  • Optimize the use of current capacity

  • Reduce production costs

  • Reduce inventory

  • Increase visibility across departments

  • Improve customer response time

  • Payback typically less than 12 months

(Yes, you can track your manual operations)

If your manufacturing operation includes manual production PlantRun can be used to monitor and track performance, including OEE, in a similar way to any other asset.