Here are some case studies of benefits that firms using LEANworx have actually seen :
1. CapEx reduction – no new machines purchased for 2 years. View case study
How a firm increased capacity by reducing machine downtime, and froze capital expenditure on new machines for 2 years, even though their orders were increasing.
2. Eliminated late starting and early stoppage. View case study
Downtime in a shop was 1 hour in each shift of 8 hours (12.5 % of the total time) due to late starting and early stopping . This was completely eliminated after LEANworx was installed.
3. Firm reduced 3-shifts working to 2-shifts working. View case study
How a firm made the same number of parts in 2 shifts, that they were making in 3 shifts earlier. Saved on personnel costs, power, etc.
It does not matter whether a firm has 3 machines, 30 machines or 300 machines. The benefits are the same.
Manufacturing production monitoring system benefits in SMEs – cost
There are Industry 4.0 systems available that come for as low as Rs. 1000 per month, or Rs. 25,000 one-time. If your machines costs Rs. 200 an hour and your downtime is the typical 40 % of a possible 22 hours, you’re losing Rs. 1760 a day. Even if you reduce your downtime losses by 25 %, your benefit is Rs. 440 per day., or Rs. 20,000 per month. This is easily achievable in just 1 month. Downtime due to work ethics issues (late start at shift start, early stoppage at shift end, extended lunch breaks, etc.) alone typically account for 12 % of the total available time, between 2 to 3 hours a day. This will reduce to almost zero in just 2 weeks.
Manufacturing production monitoring system benefits in SMEs – time to install
There are plug-and-play Industry 4.0 systems that can be connected to your machine in just half an hour, by the person who normally maintains your machines. The moment this is done, you can start seeing reports on your mobile phone, tab or PC from anywhere at any time. You can be sitting at home, waiting at a customer’s office, out of town, or anywhere. You can see what is happening on your machines 24 hours, and take immediate action. You get alerts on your mobile phone for burning issues – machine breakdown, abnormal downtime, shift production below target, etc.
LEANworx, is a plug-and-play system for SMEs, based on Industry 4.0. It is very affordable, and pays back for itself in just a month. It takes about 15 minutes to connect to each machine, and you can start seeing reports and getting alerts immediately.
A manufacturing monitoring system for SMEs not only makes sense, it is an absolute necessity to run profitably.