Automated production lines present many challenges for operations, engineering, quality and maintenance as a result of their typically hybrid manual and automated processes.

Combine these processes with mixed or batch production and often complex material flow, the following challenges can occur:

Scheduling
Sequencing
Material tracking
Ensuring first-time quality builds
Performance analysis
Data collection

Comprehensive challenges require comprehensive solutions.

PRODUCTION LINE PROBLEMS

Without Manufacturing Execution (MES) production systems, data collection and the Industrial Internet of Things (IIoT) - manufacturing production lines face multiple difficult issues. Some of the typical barriers can include:

Complex order schedules, customer demands and profitability sub-optimized for production line equipment utilization (negatively impacting production, customer satisfaction and profitability)
Labor and production means mismatched to production demands causing bloated or insufficient production resources
Out of sequence issues resulting in production loss, rework, repair, and extended production schedules
Unmonitored complex production recipes generating operator work quality errors and loss of assembly and component traceability while preventing product shipping holds
Intricate and difficult-to-remember operator work instructions - producing quality issues and ultimately production losses
Unpredicted equipment failures resulting in unplanned downtime

BENEFITS OF PRODUCTION LINE DIGITAL SOLUTIONS

Manufacturing companies benefit greatly from the high-quality MES and Supervisory Control and Data Acquisition (SCADA) functions INGENOVA360 can provide, such as: Quality Management, Work Instruction Management, Recipe Management and OEE Management.

These scalable and extensible systems can be “right-sized” to a customer’s needs and provide the following functions and benefits:

Managing production schedules and routing utilizing AI, optimizing production to customer, urgency and profitability to production line utilization
Generating and managing labor and means schedules to ensure production resources correspond appropriately to production demand
Managing production routing, product, and material tracking to prevent “out of sequence” issues (ensuring production schedules are kept, while quality data collection and product traceability provide consistency, uniformity, and historic records)
Providing operators with visual work instructions resulting in first-time quality production while reducing the need for extensive training

THINK, SOLVE, AND CREATE WITH JR AUTOMATION

INGENOVA360 Digital Solutions provide systems that allow for optimized planning, including real-time system response to changing inputs and system conditions, real-time monitoring, visualization, and analysis of operating performance and quality KPIs to enable proactively addressing issues as they arise. Having the ability to have a post-run analysis of quality data and system performance will support process, component, and system performance improvement initiative.

By collecting data from processes, people, machines, devices, and systems, aggregating that data and transforming it into information and insights, INGENOVA360 and JR Automation will give you the production line management tools to help you meet the manufacturing demands of Industry 4.0.

JR Automation has married its 40 plus years of automation development expertise with the highly technical demand of Industry 4.0, and the results are INGENOVA360.

THERE'S MORE WE'D LOVE TO SHOW YOU.

With thousands of installations around the world, we can't put everything we've done online. But there's a lot more we can share. Let's start a conversation.

Request Case Studies

Let’s start a conversation

JR Automation partners with the world's leading manufacturers to design, build, and integrate custom automation solutions. Time and again, we've proven that hard work and creativity can uncover opportunities others never thought possible.

Email us: [email protected]

Call us: (833) 800-7630