In any company, especially in the industrial sector, there are many areas to be attended, but production is one of the most important. Businesses face the daily challenge of manufacturing products according to deadlines, characteristics and quality standards.
Unfortunately, many companies in this sector have problems related to the productivity and efficiency of their production processes. Therefore, understanding the uniqueness of each company, there are a number of common problems that affect most industrial businesses.
However, not all companies deal with production issues or problems in the same way. In this article, we tell you how to reduce production failures in the industrial sector, exposing and comparing the different ways to minimise errors in this process.
Techniques and systems to reduce production failures
There are several ways to reduce failures and/or defects in the industrial production process. These are some of the traditional techniques to avoid incidents and unforeseen events in the production chain:
Preventive measures. Replacing obsolete equipment or renewing machines that are beginning to fail permanently are some of the most basic measures that companies adopt to prevent future problems. However, this type of technique can be very expensive for the maintenance team, who will be constantly carrying out check-ups and possible replacements of machinery that will frequently interrupt the production process.
Regular inspections. Regular inspections are part of the previous point. Every company should have a maintenance team that is dedicated, at least on a regular basis, to monitoring the machinery to ensure that it is in good working order at all times. However, it is worth considering whether such measures are sufficient and, above all, 100% efficient.
Attend to communication flows. Communication is essential in any company to ensure good management. Maintaining positive and constant contact between production employees and the rest of the departments is a basic point to avoid future errors.
Maintaining quality controls. Innovation in product design and other aspects are useless if the production line is not regularly controlled. In this sense, every company can choose between different types of industrial maintenance to keep the quality of production:
- Corrective maintenance.We know this type of maintenance as that which corrects incidents as they arise. This is the most basic system of all, although it is also the least efficient.
- Preventive maintenance. This technique is also one of the most common and is based on avoiding failures due to wear and tear, avoiding a certain number of breakdowns due to deterioration. Normally, this type of maintenance includes all the measures mentioned in this section (regular inspections, preventive measures, etc.).
- Predictive maintenance. Predictive maintenance appears as a new technique that makes use of artificial intelligence, detecting anomalies in the operation of assets to anticipate possible failures or incidents in production equipment. This system is the most advanced and increasingly used in smart factories.
In addition to industrial maintenance management, the digitisation of processes and facilities is increasingly present today. We invite you to get to know Smart Manufacturing.
Above all other techniques, there is the possibility of digitising your industrial company and, with it, being able to Smart Manufacturing.
Smart Manufacturing is a set of collaborative manufacturing systems that respond, in real time, to the changing needs of factories, including predictive maintenance.
In this new concept that embraces the Fourth Industrial Revolution, cutting-edge technologies such as Big Data, IIoT or Machine Learning are applied to address a more flexible, modular and optimised production.
Is it worth digitising your factory to reduce production failures?
Today, companies need increasingly interconnected, flexible and adaptable systems that help to reduce production costs, increase efficiency and get the most out of production processes. That is why, above any other technique, turning your business into a smart factory will always be the best option to achieve greater efficiency.
Digitising your industrial company will make production processes more streamlined, faster and more efficient. Traditional maintenance techniques are less time-consuming, but involve higher costs – direct and indirect – and time-consuming for the team, which can be avoided by relying on an integrated operations platform such as Nexus Integra.
If you are considering digitising your production and/or industrial facilities, contact our specialised team to receive advice and offer you a solution adapted to your needs.