Written by Kumari Trinavee

Business Challenges Addressed

In the current competitive market, manufacturing companies face fluctuations in customer demand. The requirements for a product or product families could explode dynamically or, conversely decrease and manufacturing organizations being able to respond rapidly to such variations becomes an absolute necessity. The question that arises is – How to achieve target production outputs on time when challenged with fluctuating demand while maintaining desirable manufacturing efficiency? How to evaluate the complex manufacturing processes and input variations? In such an environment, measurement of equipment failure, rejection rates, machine downtime due to shortage of raw material supply or shortage of labor, productivity rate per work center, labor overtime rate are some of the parameters that become crucial and contribute to achieving the manufacturing goals. Parallelizing the production volume with the customer demand quantity ordered is another concern. Decisions and Results for production goals are dependent on many parameters and some of them are complex. Hence, dashboards are essential to manufacturing plants to visualize their data in different ways, track important metrics and key performance indicators (KPIs) that align with their business objectives and help them assess their performance. This visual cue is important, as it helps to interpret the problems faster. A smart, well-constructed dashboard would be able to show the pain points and bottlenecks that are hampering the manufacturing objectives.

Manufacturing Dashboard Outline

A manufacturing dashboard is a connectivity tool that allows tracking and tracing the productivity levels of a manufacturing process, which helps decision making by providing real time data. Manufacturing dashboards provide real-time visual representation of a manufacturing process. Manufacturing dashboards combine graphs, tables, and other visualization techniques to make production KPIs easy to understand. They organize data from machines, sensors, devices, and workers into easy-to-read, instantly available breakdowns that the whole operation can reference. Monitoring the operations with real-time visual representation in the dashboards can help ensure correcting inefficiencies, recognizing areas for performance improvements, and collaborating with team members effectively. DELMIA Apriso’s Dashboard Builder is a unique and powerful drag and drop tool that allows to present manufacturing data using data visualization techniques that exhibit appropriate and actionable data.

Who are the key beneficiaries?

This dashboard can be designed for different groups of manufacturing users. Dashboards provide top-level management in directing and managing business growth and performance by providing a snapshot of current conditions, which is vital in forecasting and capacity planning. Plant management and production supervisors can get-a-glance status of various manufacturing operations and systems directly and leverage the data to monitor efficiency in the production process or assembly line and alert key personnel of situations that require their immediate attention. Shop floor operators use these dashboards to access real-time data and monitor critical performance parameters of the machines.

How do interactive dashboards work?

Interactive dashboards are suitable for manufacturing plants of all size and nature. The Dashboard Builder enables an easy way to build interactive Business Intelligence Dashboards from within the DELMIA Apriso Desktop Client (ADC). Once in the Dashboard Builder, the user can create a new Dashboard or modify an existing dashboard. This self-service analytic tool is designed to ease all the phases of data binding and shaping (including user interface layout). DELMIA Apriso’s Dashboard Builder enables you to build manufacturing dashboards using drag & drop, customize dashboards with a few clicks. Auto Refresh functionality refreshes the data in each report to display up-to-date data in the dashboard. The user can set the interval time (in seconds) while designing the dashboard. This allows the business user to deliver professional business-oriented Dashboards without a large learning curve. Because some of the data could be sensitive, access to Dashboards would need to be controlled using DELMIA Apriso Roles.

Dashboards can be constructed utilizing a wide range of visualization elements, including:

  • Pivot table
  • Charts
  • Cards
  • Grid
  • Gauges
  • Range filter
  • Sparklines
  • Shapefile maps
  • Calculated fields

A real-time view of multivariate data using interactive Business Intelligence Dashboards from within the DELMIA Apriso Desktop Client (ADC) lets the manufacturing plant track and monitor easily the current manufacturing operations.

With manufacturing dashboard(s) as presented below, we can visualize the right analytics at the right moment collectively in one dashboard as shown in Production Dashboard or individually (e.g., Shopfloor Orders, Reasons for Rejection), incorporate data into reports and share across organizations for in-depth analysis. The Production Dashboard presented below is an example of one of many dashboards designed for one of our customers. Knowing the overall Production Volume is an important first step. This gives the idea of what the active machines are dealing with on a daily, weekly, quarterly, monthly or annual basis. The Table with Grids represents the data for the Order Details associated with the different Work-Centers, Part numbers along with the size of the Handling Units (HUs) for the corresponding order. When it comes to production, we need to know about the equipment and take extra-care of the most productive ones. At the same time, every machine needs maintenance and care, irrespective of its contribution percentage to the production volume. The data visualization with the Chart shows the Shopfloor Orders and workload on a Work-Center using order volume and unique Part numbers. When the manufacturing efficiency of the factory is evaluated, a key step would be to assess their quality. Monitoring the quality of the production is then another major concern. The Pie chart in the Production Dashboard shows the different reasons responsible for rejection of parts and can be tracked to find the major concerns. Manufacturing dashboards offer flexibility and will help manufacturing organizations stay competitive, stable and up to date in the global platform and help the business stay lean.

In the illustrations below, a real-time Production Dashboard example is presented using one week of production data to highlight what can be built using Apriso Dashboard Builder and help customers manage their business effectively.

 

Figure 1 ‘Production Dashboard’ illustrating data with Grid, Chart and Pie Chart in one Dashboard

 

Figure 2: ‘Order Details’ illustrating data using the visualization element as Grid

 

 

Figure 3: ‘Shopfloor Order’ presenting data using the visualization element as Chart

 

 

Figure 4: ‘Reasons for rejection’ demonstrating data using the visualization element as Pie Chart