Manufacturing Business Analytics

Overview
Intelligent manufacturing is achieved through identifying the overall effectiveness of the manufacturing operations - from the shop floor through to the top floor. Tying machine level data to inventory and batch level production mandates will provide a holistic view of the entire manufacturing operation Transforming the real-time, historical and business data collected during production activities through the KeyTone SmartWIP platform will provide the synergy between intelligence and execution - the ability to take decisions based on intelligent manufacturing data. The responsiveness and agility that organizations can realize through analytics on the data collected through SmartWIP during manufacturing will prove to be invaluable in increasing yield and achieving six sigma objectives.

Production Management Analytics
Production management analytics is tracks all aspects of the manufacturing production. Developed for management it will provide historically accurate records as well as real-time information of the production process including details of defect tracking and complete product genealogy. In doing so it will enable the communication of real-time manufacturing data from the shop floor to the decision makers when they need it. 

• Business risk management - allowing backward and forward traceability of any given serial number or materials purchased from a vendor, permitting manufacturers to monitor the entire history of materials used to produce a product 
• Inventory management - allowing the tracking of all inventory both in WIP and in pre-production 
• Scrap management - enabling personnel to track the efficiency of production and estimating the cost of quality through the production process 
• Quality Assurance - enabling personnel to track a consistent output of sensible quality to help ensure that products are built with the right materials in the right processes. 

Example Metrics - Lot History, Production Inventory by product, WIP Inventory by process, Non Lot Inventory by product, Shipping Inventory, Non Lot Scrap by product

Production Performance Analytics
Production Performance analytics addresses the need for accurate real time asset performance analysis on the plant floor, thereby speeding up the decision making and planning processes. The information made available assists in the achievement of world-class manufacturing practices by clearly identifying downtime duration and reasons, generation of production performance against plan reports, calculation of quality performance and monitoring overall equipment effectiveness. 

The fundamental data elements of performance management analytics are derivatives of manufacturing Key Performance Indices (KPI). These elements of information define the important operational factors of the machine, production line or manufacturing process. 

• Optimize throughput even in high-mix conditions by using the real time validations of the products by station 
• Cope effectively with change by automatically viewing the impact of a process change within the production process 
• Tighten your grip on shop floor execution by using the real time alerts and process monitoring through the intelligence dashboards 

Example Metrics - Production Rate Performance, Asset Yield, Asset Utilization and Overall Equipment Effectiveness. Equipment Utilization, Equipment Reliability, Equipment throughput, Equipment MTBF, Equipment MTBA, Total defects by tool, Total rework by process, Total rework by tool, Defects by lot and Defects by product

Production Operation Analytics
Manufacturing process analytics enables the improvement of overall profitability and effectiveness in manufacturing operations by providing information on several critical, interrelated areas of production. These areas include the ability to better utilize plant assets (such as people, equipment and materials) through a single or multi-site view of overall equipment efficiency 

• Enable route validations to ensure there are no deviations from the determined process routes within the production environment 
• Perform real time data validations on all products. Lots and products that pass preset tolerance thresholds can automatically move to the next process step 
• Analyze production information and get to the root cause of issues to rework products in real-time to increasing first pass yield and your cost margin 

Example Metrics - Equipment status, Equipment availability, Lot Report By station, Defects by tool, Lot Inspection History and Process validations