How to Leverage the Internet of Things to Impact Plant Profits
A strong majority of manufacturing executives say the application of Internet of Things (IoT) technologies to plants and production will increase profitability in the next five years. Some 26% expect profit boosts of more than 5%.
Unfortunately, many of these imagined profits will never materialize.
Because nearly a quarter of manufacturers have no companywide understanding of the IoT and how to apply it to their businesses. Another 43% have only limited understanding.
Even worse, only 11% of manufacturers have implemented a strategy to apply IoT technologies to their processes. Small and midsized enterprises (SMEs) are even less likely to have companywide understanding or IoT strategies.
Yet gloomy as these numbers might seem, they offer insights into improving your IoT prospects:
Develop IoT knowledge: Spur awareness and understanding of the IoT throughout your company by focusing on how embedded intelligence and smart devices can drive improvement — on the plant floor and in the office. For example, real-time data on production can allow for delivery updates to customers. Or maintenance staff can monitor key equipment to predict failures, and prevent line stoppages.
Communicate an IoT vision: Establish a collaborative, integrated plan for your company to help managers and employees understand the IoT’s potential, develop an company-specific IoT strategy, and budget for IoT investments (and ROI).
Implement an IoT strategy: SMEs have a big IoT advantage, since they have fewer workers to train, and fewer machines and systems to connect. Even so, most SMEs can’t afford to make every new asset “smart” right out of the gate. Instead, implement your IoT strategy in phases, with improved productivity and cost savings from each project helping to fund the next phase.
One remarkable thing about the list is that it rarely changes. The order may change but the top cited standards typically don’t change. Top 10 Sited Safety and Health Violations: 501 - Fall Protection 1200 - Hazard Communication 451 - Scaffolding 134 - Respiratory Protection 147 - Lockout/Tagout 178 - Powered Industrial Trucks 1053 - Ladders 305 - Electrical, Wiring Methods 212 - Machine Guarding 303 - Electrical, General Requirements Three of the 10 sited standards are directed at the construction standard (1926) while other fall within the general industry (1910). It should be noted however that the general industry standard also has fall protection guidelines. Year after year, inspectors see the same on-the-job hazards, any one of which could result in a fatality or severe injury. More than 4,500 workers are killed on the job every year, and approximately 3 million are injured. By understanding these regulations you can improve your safety program and prevent injuries. Give me a call if you have any compliance doubts, or want to review OHSA regulations. Gwido Dlugopolsky at 216-391-7766 or firstname.lastname@example.org
Why does it take a NASCAR pit crew only 15 seconds to change four car tires when it takes people like you and me minutes? The answer is simple SMED. Single Minute Exchange of Dies, or SMED, is a process for reducing the time it takes to do equipment changeovers. Using the principles of SMED you should be able to perform any changeover in your facility in under 10 minutes! The SMED process is simple – convert as many changeover steps as possible to “external”, meaning they are done while your equipment is still RUNNING, while simplifying and streamlining the remaining steps. SMED is broken down into the following 3 Steps: Separate Convert Streamline We found this article to be very helping in explaining the SMED process in more detail: LEAN PRODUCTION - SMED A good first step to achieve this level of SMED efficiency would be to run a kaizen event at your facility to standardize (5S) your tools and supplies. Doing this alone will help you achieve 40% to 50% greater efficiency. Once the “low hanging fruit” is gone, you can still reduce setup times another 20% by practicing more advanced SMED principles.
The secret to closing any sale is to reduce uncertainty in the buyer and replace it with confidence in YOU, your PRODUCT/SERVICE, and your COMPANY. Step 1 – Confidence in YOU Someone buying from you wants to be able to fundamentally connect with you on a human level and feel confident that you’re an expert in what you’re selling If you’re selling paperclips, be an expert in paperclips If you’re selling design and engineering related services, be an expert in design and engineering related services Focus on addressing the problem, not the solution….MEANING you already know you have the solution, connect with the buyer by being an expert with the problem he/she is facing. Prove that you know the problem and all aspects of the problem like the back of your hand. Step 2- Confidence in the PRODUCT/SERVICE you are selling Someone buying from you needs to trust the product/service you are selling will solve their problem. It’s your responsibility to deliver a solution and the benefits associated with it. Basically you need to “Hit a Homerun” communicating this message. Tip – Use Success Stories: Share with the potential buyer examples of your product/service solving problems and delivering value for