Data is the backbone of smart manufacturing, connecting machines, assembly systems and processes. But it is often overlooked and unappreciated; until it’s too late.
Picture this: the line is running and output targets are being met. But weeks later, a quality issue emerges and no one can identify what happened.
Whilst tool failure is often glaringly obvious, (you can see when a tool isn’t working) missing data or “data downtime” is a different story. It can be harder to spot as there often isn’t an immediate consequence, but just as costly.
What does missing data in manufacturing look like?
Spotting that you are missing data on the line early can help you avoid costly quality issues. Here’s some quick identifiers to keep an eye out for:
- Incomplete reports
- Gaps in product history
- Stalled dashboards, delayed events, silent alerts
Why does it matter?
If you have noticed these patterns, it could be easy to dismiss them as IT issues, especially if you’re a manufacturer more familiar with tool downtime.
However, they may cause issues which impact your line:
- Broader recall scope due to lack of traceability
- Longer root cause analysis
- Compliance risk and audit exposure
- Loss of confidence in systems
If the issue isn’t resolved quickly, it can spiral causing quality, compliance and financial risks, and before you know it, it’s spiralled into a complete loss of control.
The cost of missing data is often referred to as hidden because it isn’t one specific event, like a single tool failure which physically prevents you from continuing, instead it is a whole series of possibilities and can cause a chain reaction.
How to prevent missing data
Our Avantguard software detects errors and guides operators through complex tasks, as well as through the repair process. ALTURE can analyse trends to give you proactive recommendations to help you enhance quality, maximise uptime, and improve FTT.
Traceability also ensures full accountability. You know exactly which product is impacted, the stations and tools that touched it, OK/NOK tightening results, as well as any changes in tool programmes or parameters and when they took place. Whilst reactive models only measure visible failures, proactive data monitoring reduces events that would have created cost which often conceals their value.
“Nothing happened” is not proof you do not need preventative maintenance; it is proof that it is working.
If preventative maintenance is working, what should you see?
Instead of focusing on how nothing went wrong, there are some tangible indicators you can look out for to measure the value of your preventive maintenance. A useful starting point is to look at three indicators most manufacturing teams already recognise:
As well as our three indicators to look out for, we offer TechCover. A complete software maintenance agreement for all your needs. It provides proper software support and efficient solutions to keep your software up and running, improving quality, productivity, and system uptime.
Learn more about how to understand the true cost of your service model.