Recently, we finished a comprehensive case study with Versatech – a full service engineering, manufacturing, and consulting company – who recently launched a company-wide initiative to leverage data more effectively to reduce overtime and improve manufacturing production and efficiency. In this article, we’ll highlight their manufacturing engineering efforts, approaches, and results inside of the overall initiative.

manufacturing production analytics

Manufacturing production and analytics

“We wanted to use data better to look at downtime… make sure machines are running properly… and focus on improving machine up time and reducing downtime”, said Scott Strutner, Manufacturing Engineer at Versatech. Versatech elected to implement SensrTrx Manufacturing Analytics to aid in the process of tracking up time, scrap rates, and machine performance in real-time. They were also using the technology to monitor OEE trends over time, by cell, machine, and more.

“From my seat, I use SensrTrx as a tool to see if the changes being made are making a difference. It does allow us to see where OEE and downtime is trending…” – Manufacturing Engineer, Scott Strutner

Ultimately, Versatech wanted greater visibility into what was happening on the shop floor. They wanted to see machine performance and up time in real-time so they could adjust and affect problems as they occurred; not after the time for savings was lost. They also wanted to be able to see OEE and manufacturing production trends over time. This department used SensrTrx dashboards to easily see how changes they were making would affect OEE – both positively and negatively – without manual tracking or retroactive guessing.

manufacturing analytics case study info

Better data, better results

By leveraging the dashboards and centralized data inside of SensrTrx, the manufacturing engineering department was able to better track machine performance and OEE trends, and were able to increase their OEE by +30% in a matter of months.

“Overall, I think SensrTrx has had a massive impact. It is a great tracking tool, but I think the bigger impact is that it helps us easily focus the feedback from production on issues and areas for improvement ” – Strutner continued

SensrTrx dashboards allowed Versatech to view high level stats they needed to be track and the ability to look at the history of their fluctuations; allowing them to look at what caused positive or negative impacts at a very granular level. This allowed them to look at last month in comparison to the current month, do trend analysis, and track total downtime.

The next step

This positive experience using data has only made Versatech more excited about the possibility of using machine data to improve their business practices. Versatech CEO, Chad Hill, was quick to point out that one of the next step for leveraging data on the shop floor would include using data inside of SensrTrx to impact on/off state utilization of machines.This would allow them to optimize machine efficiency at an even greater level than they are today.

Use it (SensrTrx data) and integrate it into your daily/weekly processes – Strutner emphasized

The wrap up

The full case study (and all the associated processes and cost-savings information) is located on this manufacturing analytics case study page. If you’d like more information about SensrTrx you can contact the organization today about starting your trial to see if manufacturing analytics and better data could impact your manufacturing production department.