Introduction: Complexity in OEM Manufacturing TodayOriginal Equipment Manufacturers (OEMs) are caught in a perfect storm of complexity, quite a challenge. Manned against a global competition, a relentless pressure for faster innovation, and ever more volatile supply chains, they are facing a completely revolutionized manufacturing scenario. Customers want differentiators, i.e. mass, customized products of perfect quality, and at the same time, there is an increased cost pressure. In such a high, stakes environment, it is no longer a viable strategy to rely on intuition and legacy systems. Data is the new competitive frontier. Intelligent analytics is fast becoming the essential beacon guiding OEMs through the murky fog of operational complexity and leading them to the future of predictive, efficient, and agile manufacturing. Essentially, it’s the change of mindset from problem solving to opportunity seeking.
Challenges with Traditional Manufacturing OversightManufacturing oversight has been largely the catching, up phase game for decades. Managers are generally forced to piece together their understanding of the past from a combination of manual reports, disconnected spreadsheets, and summaries of the end, of, shift. It is a reactive approach that brings challenges stifling growth and draining profitability.
- Information Silos: Data gets enclosed in different systems. For instance, the maintenance team uses its CMMS, quality has its QMS, and engineering operates with its PLM software. These systems do not talk to one another, hence the single, fragmented and usually contradictory view of the real world.
- Delayed Reaction to Problems: Results defects or breakdowns are only detected after the event leading to considerable losses. Hence, time, consuming, root cause analysis becomes a post, mortem investigation rather than a live intervention.
- Manual Data Gathering: Operators and supervisors are occupied with manually recording production counts, reasons for downtime and quality checks. Such a process is liable to mistakes by humans, and also, it misdirects the attention from the activities that add value.
- Lack of Real-Time Visibility: Executives and plant managers do not have a clear and up, to, the, minute production status picture. They have to resort to a series of phone calls to be able to answer essential
- questions like “Will today’s production target be met?” or “Where is the bottleneck in the production line?”
This conventional framework induces a permanent condition of confusion, which hinders OEMs from making the most of their production
Read More :- How Intelligent Analytics Is Transforming OEM Manufacturing Operations
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