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Monitoring of operational processes in production
A system for analyzing performance, downtime and costs through real production data.
System overview
In production systems, data exists but is often fragmented between:
machine,
operator,
production lines,
and various records.
The goal of this project was to build a central system that collects real data from production and turns it into a clear overview of performance and costs.
The system allows management to see what is really happening on the ground — not in theory, but in actual work.
Why is it important?
Without system monitoring of production:
downtimes are not visible in time,
losses are not quantified,
performance is evaluated subjectively,
costs are rising for no apparent reason.
This system allows:
transparency of the work of machines and people,
measuring real productivity,
and cost control by lines and shifts.
Our approach
How we approached the problem
The project was started by mapping production flows:
- what operations are there,
- where delays occur,
- how performance is measured,
- and how losses are recorded.
Based on that, a system was designed that connects operational data into a unique model.
Key system components:
- Record of work of machines and operators
- Tracking of production orders
- Analysis of bottlenecks and bottlenecks
- Performance measurement by lines
- Cost tracking by phases
- Reports for shifts, days and periods
Results and effects
After implementing the system:
Downtimes are clearly visible and measurable
Performance is monitored objectively.
Management has a realistic picture of production
It is easier to plan capacities
Decisions are made based on data, not estimates
The system becomes the basic tool for operational production management.
Typical questions that the system solves
Where exactly are we wasting time in production?
Which lines are the least efficient?
What are the realistic downtimes per shift?
How does performance change over time?
Which processes generate the most costs?
The project
Operating system for production
CoreLayer Solutions
We build systems that connect data, processes, and decisions in a real-world business environment.
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Phone
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upiti@corelayersolutions.org