Manufacturing Efficiency with SMARTUNIFIER

In the intricate world of manufacturing, where precision and quality are paramount, high-variance product manufacturers face a relentless challenge – ensuring the accurate tracking of serialized items, consumables, and manufacturing equipment. Despite the existence of Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) systems, identifying root causes for quality issues remains a formidable task.

Quality problems persist even in well-run systems, arising from issues like temperature instability in tooling machines or supplier variability affecting product quality. In such a landscape, a holistic solution for the IT integration of all types of equipments and machines to capture and process a large amount of all meaningful data is imperative to elevate efficiency and enhance quality in the manufacturing process. Enter SMARTUNIFIER – a revolutionary answer to these challenges, redefining manufacturing efficiency.

Analyzing the Root Causes of Quality and Yield Problems in Established Systems

Quality and yield problems are not uncommon, even within well-established systems. Various factors contribute to these issues, ranging from temperature instability in tooling machines to supplier variability. For instance, consumables from different suppliers with identical specifications can impact product quality. The crux of the matter lies in the difficulty of conducting in-depth analyses to pinpoint the root causes of these problems, despite the existence of sophisticated management systems.

What is the traditional way of dealing with this? When a quality problem is identified, the investigation begins. Task forces are formed, and data analysts, process specialists, and development engineers come together to hypothesize what could be the cause of the problem. A root cause analysis is created as part of an 8D report, FMEAs are analyzed, expert opinions are obtained, and data analysts gather information on all data sources that could help find the cause of the problem.

The analysis or the creation of the proof begins based on 5-Why. Even if very experienced experts are at work, in most cases a data analyst is not an SQL expert per se and is therefore not able to write SQL queries with all data sources, filter criteria, and data conversions to the point. A lot is done „hands-on“. This approach takes time, experts are distracted from their actual task during this time, while the product in question may still be in production. Days after the start of the task force, results are offered and measures are initiated.

Addressing Manufacturing Challenges with a Holistic Strategy

To tackle these manufacturing challenges effectively, a comprehensive approach is imperative. It goes beyond merely orchestrating production orders and managing batches of consumable goods. This holistic strategy aims to enhance both efficiency and quality throughout the manufacturing process.

An important part of this strategy is to carry out data contextualization at such an early stage that the information is stored in a way that is suitable for analysis without the need for subsequent time-consuming research. Contextualization means that correlations between semantically related data are known, mapped, and stored from the outset. For example, the workroom temperature must of course be linked to the respective production batch or order, as must the batch number of the consumable used. This early contextualization is an essential key to increasing the efficiency of root cause analyses.

The second part of the strategy relates more to the IT infrastructure. While centralized data storage makes sense, decentralized data acquisition should be the solution. In the production environment with highly distributed sensors, decentralized acquisition, which provides high-performance channels for communication, is preferred. Centralized message bus solutions are quickly overwhelmed by the high throughput capacity required.

Boost Manufacturing Efficiency with Decentralized Connectivity and DataOps

Imagine a solution that connects all facets of the manufacturing process, from equipment to cloud IT systems, and goes beyond, offering a fully decentralized architecture and a cutting-edge DataOps platform. SMARTUNIFIER is more than just connectivity; it’s a comprehensive approach designed to transform manufacturing efficiency and sustainability.

Unlocking SMARTUNIFIER Benefits

The benefits of SMARTUNIFIER extend far beyond its connectivity capabilities. Let’s explore how this ground-breaking solution revolutionizes manufacturing processes:

1. Reduced Integration Efforts: SMARTUNIFIER minimizes the integration and connection efforts thanks to equipment and device-independent information models. This ensures a smoother implementation process for manufacturers.
2. Out-of-the-Box Industrial Connectivity: With support for a high number of protocols and applications, SMARTUNIFIER provides industrial connectivity that is ready to use, reducing the time and effort needed for system integration.
3. Adaptable IT Architecture: SMARTUNIFIER’s decentralized approach supports almost any kind of company’s IT architecture. Whether it’s edge, on-premise, private, or public cloud solutions, this solution seamlessly integrates with diverse IT environments.
4. Efficient Data Analysis: The contextualization of data close to its creation time significantly reduces data analysis efforts, enabling manufacturers to derive meaningful insights with efficiency.
5. User-Friendly Configuration: SMARTUNIFIER’s low-code/no-code approach ensures that even non-IT administrators and programmers can use the solution effectively, reducing configuration efforts and promoting widespread adoption.

The Impact of SMARTUNIFIER on Manufacturing Efficiency and Sustainability

As manufacturers navigate the complex landscape of high-variance product production, SMARTUNIFIER emerges as a transformative force. Its decentralized architecture, sustainability focus, and benefits redefine manufacturing efficiency and pave the way for a sustainable future. SMARTUNIFIER is not just a solution; it’s the key to unlocking a new era of operational excellence and environmental responsibility in manufacturing.

Ready to revolutionize your manufacturing process? Experience the power of SMARTUNIFIER and unlock a new era of efficiency and quality. Take the first step towards operational excellence – explore SMARTUNIFIER today.