Production loops can surface within any manufacturing sector, from pharmaceuticals to aerospace. The costs and implications of production loops can be detrimental to a business, meaning it is vital to acquire a stringent testing process to identify errors and meet those output expectations.
Production Loops
In manufacturing, production loops generally materialise because of an error or an unknown, resulting in a good or component having to be remade or reworked. As high investments are spent in design, production and delivering a product, all components must match the specification, even the smallest defect or error could have damaging effects. Errors can happen due to defective equipment or material issues. For example, a batch of materials may unknowingly be of lower quality and therefore too weak for its intended purpose, leading to sub-standard products.
Production Errors
Production loops cost manufacturers unnecessary expense, the time spent re-manufacturing or fixing a product or component leads to additional costs and delayed output.
Remaking a component essentially doubles the cost and time to dispatch and delays other goods that were planned to be on the production line at that time. Brand reputation, customer relationships and trust are paramount to profit and growth. Delays to customers receiving their goods can drastically impact brand reputation and, in some circumstances, could even lead to clients going elsewhere.
Alongside this, defective products arising creates excessive consumption of materials and energy, significantly affecting profitability. These losses not only impact performance and production costs but also directly increase the carbon footprint with the additional CO2 emissions that are released.
Identifying the Root Cause
JetSoft’s solutions create visibility over the production line, which enables manufacturers to operate more reliable production and mitigate production loops. By centralising inspection data alongside vital production data, our OverSeer framework can derive further intelligence on your operations manufacturing process.
To receive detailed inspection data, our solution DigiOps allows manufacturers to digitise the inspection process, collating all the data formats into the OverSeer platform, where it will be combined with the array of production data you have available. Our specialised machine learning algorithms will analyse all the data inputted, in order to spot anomalies to identify common problems occurring.
1. Reduce Extra Production Costs
As an example, our solution may find that products going through equipment are experiencing higher inspection failure rates than those on other lines, indicating a problem with the equipment. Our solutions can help you identify exactly where a defect is originating by integrating inspection alongside other manufacturing data, so that maintenance of equipment can quickly take place to prevent another component facing the same failure and therefore the associated costs in re-make.
2. Minimise Delayed Output
Digitising paper-based processes through our solutions helps you to gain end-to-end visibility of all inspection data, to make quick and informative decisions. If a material defect rate is higher from a certain supplier, alternative materials may be sourced to ensure fewer defects and thereby fewer delays.
3. Reach Net-Zero
JetSoft can help you meet those looming carbon emission targets. Gain complete control and traceability over your inspection and manufacturing data, to identify the root cause of any production-related complications before they become a production nightmare. OverSeer can help you drive sustainability, by increasing quality control, spotting defects earlier on and where from, minimising the chance of a production loop. Fewer production loops mean the associated energy required is taken out of the equation and so are the carbon emissions.
4. Meet Customer Expectations
OverSeer curates an in-depth data process through our user-friendly analytics dashboard, allowing you to input all formats of data, from complex 3D images to the simplest of forms. Our solution can cross-compare real-time and historic data, to monitor trends and help you gain in-depth insight to produce high-quality products. Minimising production loops is integral to reaching quality controls to exceed customer expectations and stay ahead of competition.
A Framework for Success
Implementing a digital framework is critical to driving efficiency in your production line and paramount to reducing production loops.
By deploying JetSoft’s solutions, you are able to identify defects to improve future production processes, increasing your output and decreasing waste. High-quality and reliable output will create major opportunities to gain a competitive advantage in the manufacturing landscape, get in touch to find out more.
