Too often, smaller companies are intimidated by the high costs, complexity, and long installation times that high-end smart factory systems can require. This is short-sighted. Companies can see big financial benefits by utilizing existing data and simpler technologies to reduce waste, labor costs, overhead, and utility expenses.
Start by identifying the business issue you are trying to solve. Companies should focus on the factory P&L and identify KPIs and metrics that directly impact on it. The next step is to figure out how to apply smart-factory concepts and tools to improve performance on those specific benchmarks, which typically include overall equipment effectiveness, machine/asset utilization, productivity, and throughput.
A major cause of waste, for example, was baked goods that came off the line underweight or overweight . By installing digital scales and sensors on the existing manufacturing line, the company caught that waste before it was baked in — reducing scrap by 25%.
We have seen this combination of capabilities work time and again. A couple of years ago, we worked with a east coast metal products manufacturer in the U.S. with roughly $100 million in revenue that was overwhelmed by orders when Covid disrupted its overseas competitors’ supply chains.
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