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What Is A Shop Floor Data Capture System And How Does It Drive Roi?

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By Author: FitFactory
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Shop Floor Data Capture (SFDC) is a system used to track, record, analyze, and control the work in a manufacturing unit. It will usually work in tandem with a production control or MRP system to simplify communication and improve the visibility of your shop floor. Many production units not using SFDC as a tool to govern and command their production line more efficiently are missing out on a huge amount of information about their manufacturing process. Those who haven’t tapped into the usage of SFDC software are also losing on the gain of multiple benefits like:

Real-time work progress tracking
Identifying accurate and complete product costing
Streamlined communication between shop floor and production office
Productivity analysis of each employee, task, and work center
Detailed analysis of completed tasks and work-in-progress
Planning accuracy improvements

 
Does your production plan work exactly as you think, or do you just react?
Managing and controlling production is a strenuous job.
The competition in the market is sky-scraping, and the pressure of making quality deliveries on-time and on-budget is even higher. Unfortunately, the pressures do not end here for a production manager. As well as this, the internal issues of production like poor quality, high cost, and machine capacity, cause multiple headaches for manufacturers. In many companies, these errors only appear when disaster strikes. The administration is not even able to track the exact place of these issues in their production line. Ultimately, without visibility, manufacturers face a substantial risk of loss in their business.
Identifying the bottlenecks in the manufacturing process and alleviating them in time is imperative. However, in this technology-driven and fast-paced business world, you may not get time to go for a roundup to the entire plant and analyze each task and process to identify delays and errors. There must be a fit-bit type solution that has the power to serve you everything at the precise moment you need it.
 
You are lucky! A Shop Floor Data Capture system can serve you everything on your couch.
There are multiple software solutions available in the market, but not all are equivalent in terms of quality, performance, and pricing. One may provide you with excellent performance but not fit your budget, and there can be many other things to consider. So, now the question arises of how to select perfectly tailored shop floor data capture software for your production hub!
 
FitFactory keeps your factory astonishingly fit by its factory management system.
A shop floor data capture system is only part of your shop floor management, alongside a production control system. So, it makes sense to consider both together. The right system can make it seem like it’s an extension of your production control system. Capturing everything the shop floor operatives do, sharing job instructions and logging corrective actions efficiently. With this, you can track workers’ performance, equipment usage, and streamline administrative control. But how can SFDC specifically help your business beyond an MRP system?
Key Objectives of Shop Floor Management

To ensure correct routing movement of material on the floor
Scheduling operations and resources
Streamlining the processes and procedures for optimum results
Find deviation from the standard procedure
Improve office to shop floor communication
Real-time identification of any bottlenecks and help to remedy

 
Differences in our client’s manufacturing units before and after adopting our Production Control system
 
 


Before Execution


After Execution


Deprived management of their extensive review processes.


Flawless management and seamless hold on to it.


Engineering data and manufacturing data stored in separate locations.


All information is placed according to their requirement stacks and is easily available where necessary.


Duplicates found in many tasks and processes.


A flawless process with no duplicity.


Communication barrier during information transfer.


Unblemished information transfer between authorized personnel.


Money and time lost during the creation of routings and operations for the quoting process.


Cost reduction and time-saving strategies executed in the entire production process.


Unorganized paperwork orders with zero traceability throughout the department.


Centralized decision making and authorization makes the process more efficient and free from unauthorized paperwork.


 
A Perfect Blend of High-End Solutions for Your Production Management
 
 
How Data Can Help Increase Your Production Efficiency?
A shop floor management system evaluates the resources status, machine usage, labor and other resources to report on a work-in-progress. It also allows accurate management of resources, workflow, and activities inside the manufacturing floor. The data captured and reported by a shop floor data capture system is crucial and useful to the managers for improving the overall process. Additionally, data gathered on the SFDC system helps to increase the worker’s productivity, reducing throughputs and cycle time. When the productivity of labour is increased and the use of resources is optimized, the operators can get more time to plan their production and exceed their targets. Above all these, an attractive incentive system can further motivate and encourage the operators to meet the extended targets in time while maintaining the quality. Hence, the overall productivity of the plant will be improved like never before.
 
 
Eliminating Risks in a Manufacturing Plant
Risks are ever-present on the shop floor. From health and safety risks that could cause injury, through to machine breakdown risks that could halt production. There is little you can do to remove these risks, but with the right information, you can mitigate them and prevent these risks from causing a big impact. Our shop floor control system helps to identify risks in the shop floor environment so you can take steps to resolve them. With real-time information, managers can check the productivity of each resource and task in the process – is there an overreliance on one machine or person, for example. Furthermore, detailed analysis can be produced to identify issues through the production line – when were machines last calibrated? When did they last receive a maintenance check? On its own, this may not seem like much, and when things go right, you may not even notice it. But when you don’t have it, you surely recognize the cost of a machine breakdown that halts production and impacts delivery schedules. 
 
A Smooth Control on the Shop Floor Improves the Accountability and Responsibility
Manufacturers have a great compulsion for ensuring accountability & responsibility within their factory. And with good reason. A lack of accountability and responsibility throughout the team can lead to declines in productivity and performance. However, Shop Floor Control systems can help you to delegate accountability and responsibility while staying informed of the latest information and managing risks by exception.
 
How Does Shop Floor Control Drives ROI?
My apologies for covering the most important topic in the final section! Undoubtedly, driving Return on Investment (ROI) is what every business always thinks of when looking for a system. The return on investment of implementing a Shop Floor Control System is apparent in improved production, productivity, and more streamlined operations. It saves and optimizes time and eliminates delays & errors. A well-managed production line will definitely improve the quality and quantity. However, without the visibility of your shop floor, it may be hiding the issues. Thus, a healthy production line will drive more profit to the business.
Users of Shop floor management systems have reported up to 80% reduction in administrative tasks, reduced scrap and rework, improved OTIF delivery performance, and an increase to customer satisfaction. And, most companies begin to see the benefits within the first 1-3 months. Learn more about the benefits of shop floor control systems in these customer reviews.
Last but not the least, with the Shop Floor Management solution, managers can monitor the full breadth of all the activities on the shop floor and make better, more informed decisions frequently. Our FitFactory Shop Floor Management system can help you to gain a better and controlled production environment with improved functionalities. Check our variety of solutions today that fits best to your manufacturing plant.

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