What is 20/20 Data Collection/Monitoring & Management System?

20/20 Data Collection/Monitoring & Management System is a wireless realtime shop floor data collection and management system designed to enhance the production management to a higher level using innovative tools, allowing productivity gains ranging from %8-%13 with a pay back period in between 12-15 months.

20/20 Data Collection/Monitoring & Management System constantly monitors the operations to show and by how much specific operations or assembly stations are constraining your overall production throughput. Performance and line balancing reports rank the bottleneck stations according to their constraint on system output.

With real-time data access, managers are able to make well-informed decisions, such as reprioritizing a job or reallocating staffing. Productivity analysis allows users to measure performance and analyse labour costs by employee, operation, customer part number, work order, department, or work center.

System is built on wireless data transfer using specially designed operator terminals. Portable operator interfaces with wireless monitoring and control capabilities replace costly complex network architectures desired in plant installations. Wireless technology offers numerous benefits for assembly applications;

- Reduces installation costs and time by easily assembled wireless terminals.
- Eliminates expensive network cable material and labour costs.
- Is flexible, and enables worker mobilization.
- Provides easy and quick layout changes.
- Allows easier adds-on, removals and changes to the network.
- Is easy to access and monitor.
- Minimizes maintenance costs.
- Eliminates costs related to laying cable and conduit; such as obtaining building and safety permits.
- Enables unlimited number of work station applications.
- Reduces investment costs by decreasing terminal needs.

For the most part, a manufacturers' product alone isn't enough to distinguish it from the myriad of competitors making the same thing for less. It's a given fact that manufacturers will always have the pressure to increase productivity while simultaneously reducing costs even as the price of raw materials rises. Staying competitive with regard to pricing, and order turnaround are the two key points to keep customers satisfied. Besides, components-based enterprise applications, coupled with the ability to adopt and execute the appropriate shop floor management, are vital parts of this equation.

Real-time allows managers and executives to make informed business decisions that support their strategy. For instance, timely response to customer inquiries and requests, requires an up-to-the-minute view of WIP (work-in-process) to determine exactly where a job is and when it will be completed. As profit margins continue to decrease, it becomes critical for manufacturers to accurately measure labour hours per job - so they can improve their job costing capabilities. 20/20 Data Collection/Monitoring & Management System allows engineers/ supervisors/ managers to get the shop floor critical data on real time, empowering them with the latest data to fulfill the needs; and

- Improves productivity by leveraging production monitoring, and motivating the workers to meet the standards,
- Provides detailed analysis allowing users to monitor performance and labour costs in terms of employee, operation, customer part number, work order, department, or work center,
- Lowers overhead costs by eliminating manual data entry, eliminating data redundancy and errors,
- Allows product traceability by customer order, lot/bundle number and/or work order number,
- Enables engineers to use the reported information to determine the precise cause of any defect and the action necessary to resolve the issue,
- Provides pro-active shopfloor management,
- Reports data at the time of the event,
- Constitutes a continuous improvement tool for the managers to better lead production operations as well as continuous total quality improvement programs,
- Optimizes line balancing and flow efficiency,
- Optimizes engineering resources,
- Identifies poor operator performance before causing a problem, and trends on the job training results,
- Allows manufacturing responsibles’ access to historical information when required to troubleshoot line issues.
- Allows data backup.

20/20 Data Collection/Monitoring & Management System enables visual management by displaying the real time data in terms of various types of reports increasing decision making at a glance.

20/20 Data Collection/Monitoring & Management System also constitutes a tool for line balancing, operator on the job training, and traceability.

Line balancing;
- Throughput and product lead time reduction.
- Increase efficiency by pro-active response to online detection of bottlenecks.
- Reduced throughput time, allowing true quick response to market requirements.
- Operations measured against standard times to identify coordination issues before they affect plan output.
- Online worker performance follow-ups.
- Indicated individual operator efficiency and output.
- Improved productivity, increasing the sales value per employee
- On time delivery.

Operator on the job training;
- Skill matrix enables operator allocation, using operator query feature.
- Improves self training allowing instant feed back on operator performance and incentives.
- Allows continuous improvement on work methods.

Traceability;
- Instant detailed visibility on WIP levels at each work station throughout the plant.
- Visualizes work order/bundle/piece by station/operation.
- Visualizes each operator, hands on in every single work piece.
- Reduces scrap, enhancing production visibility.

Many manufacturers have implemented ad hoc manual data collection systems. Although better than nothing, these systems are tedious, unreliable and expensive. For example, a manufacturer of apparel goods requires operators to write down process parameters or stick labels of the quantities to a data sheet during a production run. Process data is then entered into spreadsheets manually by other operators. The accuracy of the data could possibly be questioned. Also, in the event of an incident, this data is not easy to view and trend. Alternatively, 20/20 Data Collection/Monitoring & Management System can automatically produce run records every minutes. Accuracy is assured and the data is stored securely and indefinitely.