3 Steps to Harnessing the Power of Your Manufacturing Data

3 Steps to Harnessing the Power of Your Manufacturing Data Whether you realize it or not, data is the foundation Your data can either be collecting like books of everything you do at your manufacturing plant or on a dusty shelf, or it can be transformed into organization. live intelligence with the power to impact your productivity, asset knowledge and uptime. Forget Every time you replace a filter, complete a being stumped when having to make a decision scheduled maintenance task or take a meter about when to replace that part or what’s the cause reading, data is passing through your equipment of your recent equipment failure. and back to you. If that’s the case, then there are millions or maybe even billions of data points With today’s technology, you can take 30 seconds swirling around the modern manufacturing floor. and a few clicks in a data visualization tool like Dude IntelligenceTM to get to the bottom of it and So, the question is, what are you doing with all of know what to do next. your data? With actionable data, you can see the details you In our recent Manufacturing Survey, we found some need to employ data-driven decision-making that interesting insights about what manufacturing makes a difference for your resources and ROI. operations professionals do with their asset data: To get you started, we’ve outlined three key › 14% said they have no access to their asset steps to harnessing all the power of your data manufacturing data. › 14% can view it but can’t do much with it › 15% said the data is integrated with their CMMS/EAM (and used for things like creating work orders)

Example of an Equipment Dashboard in Dude Intelligence

2 Step 1: Get Good Data

If you only have bad data, then your data is relatively useless. It’s critical that you have good data to use, and that all starts with good data entry.

There’s a saying: Good data in, good data out. That means if you’re putting in correct measurements, times, costs and more, then you’ll benefit from clean data that more clearly tells the story of your workflow.

To get good data, you first need a reliable way to capture it. Paper record-keeping is quickly becoming a thing of the past, so it’s important to have a digital system for documentation and to house all your data. A cloud-based CMMS like Asset EssentialsTM provides an online and mobile system to enter, schedule, record, track and report on every work order, asset, location, and even technicians or engineers.

It’s also critical that the system is easy to use. With today’s mobile CMMS apps, your technicians no longer have to come back to a central computer or location to enter work order information. They can input it right where they’re doing the work on a smartphone or tablet, which contributes to higher quality data.

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Your maintenance engineers are ultimately your “feet on the street” and help determine the quality of your data, so make sure they’re comfortable with the tools you give them to capture good data. When you can connect the data they gather to improved performance and insights on the back- end (and job security, financial gains, etc.), they’ll feel more motivated to work toward those goals.

3 Step 2: Visualizing the Data

You are now aggregating good data in your That’s where a modern data visualization tool like operations management system – so what next? Dude Intelligence comes in. Once you log in, you are presented with an organized and highly visual It’s time to find easy ways to use your data, but you dashboard that you can then filter by clicking on a have to be able to simply visualize and understand bar graph, or by location, employee or even a key that data first. We all know that if it’s too difficult to performance indicator (KPI) like downtime. understand, no one is going to use it.

DATA IN REAL LIFE:

Dude Intelligence gives you the data you need With this information, you can reallocate some to understand issues in a different way. Let’s say resources and better balance Rick’s corrective you’re having productivity issues, and you can’t work orders with the preventive ones. Problem pinpoint the cause. On first look, this chart tells solved! you who is completing their work late most often, so it’s easy to pinpoint Rick as your productivity Now, with Dude Intelligence, you can have a true issue. Diving deeper through the interactive understanding of the root causes of issues and the interface, you uncover that Rick isn’t being best way to solve them. unproductive — he’s just being assigned twice the amount of work as everyone else.

4 KPIs & Trends

We’re all familiar with goal setting. You may even Our data visualization tool stores KPIs right in the be required to set quarterly or annual goals at your system that are tracked by your real-time asset organization. Whether they’re around productivity, and work data, and even compared to other cost reduction or efficiency, your goals should be organizations just like yours. ones that you can track easily any day, at any time.

Here are some of the most popular KPIs for manufacturers:

Ratio of Completed PM to Corrective Maintenance

› Ratio of PM to Corrective Work — Compare your ratio of preventive to corrective work and see how you stack up with our client average. This can help you gauge if you’re doing enough PM vs. corrective tasks, so you can strike the best balance for your organization.

CAN YOU DO TOO MUCH PM? READ OUR BLOG.

MTBF (Mean Time Between Failures)

› Mean Time Between Failures & Mean Time to Repair — Find out what your average is for time between failures in your plant, and then compare to our overall client average to see if you’re failing more or less often.

5 Percentage of Corrective Maintenance Completed in 7 Days or Less

› Percentage of Corrective Work Completed in 7 Days or Less — If your team has specific goals around how many days work needs to be completed within, or if you’re wanting to establish a rule around that, this is a great KPI to look at.

In addition to KPIs, it can be helpful to view year-over-year trends to compare performance and even report on progress.

Some of our trend reports include:

› # of Work Orders › Average # of Work Orders Per Maintenance Technician › Trend of Planned to Corrective Maintenance Ratio › % of PMs Created in 30 Days or Less

This is a good way to get a high-level view of how your operations are trending and areas where you can make improvements.

Step 3: Using the Data

Now that you’re a pro at collecting and visualizing In our recent survey, we asked what type of data your data, how can you really utilize it to make your respondents need to share with others, and here processes more efficient and cut down on wasted were some popular answers: time and resources? › Equipment › Parts inventory It’s time to step up your reporting game. utilization It’s time to › Production rates make your reports simple, specific and shareable. › Unplanned Efficiency downtime › › Day-to-day With a data analysis tool like Dude Intelligence, › Safety metrics you can easily screenshot, export or even assign operations/ › Repair cost maintenance data specific reports to specific users to share the results you’re seeing. Whether you want to report on one or all of these areas, it’s all possible with a few clicks.

6 LOCATION OPEN HEAT MAP CRAFT OPEN HEAT MAP Location 0-30 31-60 61-90 90+ Totals Craft 0-30 31-60 61-90 90+ Totals Totals 26 26 27 335 414 Totals 26 26 27 335 414 Plant 1 18 18 19 229 284 Equipment Maintenance 7 7 6 93 113 Plant 2 8 8 8 106 130 Mechanical 0 0 0 1 1 - 0 0 0 1 1 Electrical 0 0 0 0 0 Engineering 0 0 0 0 0 Facilities Maintenance 0 0 0 0 0 Health/Safety 0 0 0 0 0 Heating/Ventilation/Air Conditioning 0 0 0 0 0 Lighting 0 0 0 0 0 Plumbing 0 0 0 0 0

Highlighted cells have over 5 open requests (New/In Progress/Pending: Request Date) Highlighted cells have over 5 open requests (New/In Progress/Pending: Request Date) PURPOSE OPEN HEAT MAP ASSIGNED TO OPEN HEAT MAP Purpose 0-30 31-60 61-90 90+ Totals Assigned To 0-30 31-60 61-90 90+ Totals Totals 26 26 27 335 414 Totals 26 26 27 335 414 Planned Maintenance 26 26 27 324 403 Shane Walsh 8 8 10 104 130 Production - Break down 0 0 0 8 8 Rick Grimes 3 3 2 35 43 Calibration 0 0 0 1 1 Glenn Rhee 2 2 2 26 32 0-Emergency/On Call 0 0 0 0 0 Hershel Greene 0 0 0 26 26 1-Urgent 0 0 0 0 0 Maggie Greene 0 0 0 23 23

DATA IN REAL LIFE:

What is your productivity like across multiple sites? the work orders over 90 days of the other sites. Use a heat map to view if any of your locations Drilling down shows that the majority of that is have an extensive backlog of work by looking at preventive (or planned) maintenance. Drilling down the number of days open by craft, purpose and further shows the types of PM that are getting assignee. You see that Plant 1 has more than double missed, so you can better address the issue.

Sharing with the C-suite As opposed to gut feelings or your opinion, Communicating data to executives becomes much data opens the door for better visibility into your easier when you can save and email or print a report needs and can simplify the capital planning and in seconds flat. In fact, Dude Intelligence offers budgeting process when you have the justification an Executive Summary PowerPoint that’s already you need, right at your fingertips. set up with critical analytics and KPIs from your dashboard to give you the confidence to share your Truly harnessing your data means you’re operational story and justify needed resources. solving problems before they occur, operating more efficiently and making You’ll have the tool you need to report on data data-driven decision-making a priority. the C-suite cares about like ROI, downtime, cost savings and even compliance-related work. In fact, we’ve seen clients justify resources using data like:

› 35% increase in equipment reliability › Extending asset useful life by 20% (up to 5 years)

7 The Power of Your Data

You’re creating data every second of the day, but where is it going? What is it doing to help you operate more efficiently?

Data by itself is just that, static numbers and ratings, until you find a way to organize and use it to your benefit.

With Dude Intelligence, you can harness that data to make it easier to collect, simple to visualize and actionable to help chart your future — while taking your team and leadership along with you.

Be the one to lead the way with data intelligence for your organization, so you can leave a legacy that impacts your team’s performance and the way you work for years to come.

ABOUT DUDE SOLUTIONS

Dude Solutions is a leading software-as-a-service (SaaS) provider of operations management solutions for manufacturing. For nearly two decades, our software has inspired clients to create better work and better lives. The company combines innovative, user- friendly technology with the world’s smartest operations engine, empowering our clients to protect their assets, extend the life of their machines and maximize uptime on the production floor. Today, more than 11,000 organizations use our award-winning software to manage maintenance, assets, energy, safety, IT, events and more. For more information, please visit dudesolutions.com.

866.455.3833 / [email protected] / dudesolutions.com