Real-time efficiency and operational insights are crucial for optimizing production, but gathering the necessary data can be a significant challenge. Traditional methods often involve complex integrations with machine PLCs or costly sensors, requiring heavy investments in infrastructure and setup. This makes it difficult to get the timely insights needed to improve performance.
Collecting data from machines on the production floor comes with several significant hurdles:
Manufacturer Restrictions: Some machine manufacturers place restrictions on accessing their data, forcing companies to rely on proprietary systems that are costly and inflexible.
PLC Data Access: Accessing data from machines' PLCs can be challenging due to the use of different communication protocols and limited access permissions, making data collection across various machines difficult.
Sensor Requirements and High Maintenance Costs: Adding sensors to machines involves additional investment, and these sensors often require frequent maintenance and calibration, further increasing the complexity and cost of data collection.
These challenges make it difficult to gather the data needed for effective analysis, leading to delays, high costs, and missed opportunities to improve production efficiency.
A Simple, Cost-Effective Solution: Khenda’s AI-Driven Monitoring
Khenda provides a revolutionary solution that bypasses the need for complex machine integrations altogether. Using existing security cameras, Khenda gathers machine and operational data in real-time, offering a seamless and affordable alternative to traditional data collection methods.
Visual Data Collection: Khenda uses AI to analyze video footage from cameras already installed on your production floor. In some cases, adjusting camera angles or adding a camera may be needed for full coverage of key areas, but the setup remains much simpler and more cost-effective than PLC or sensor integrations.
Automated Downtime Tracking: Khenda can automatically detect and record downtime events, capturing critical moments with video-backed data. This allows for precise analysis of stoppages and their causes.
Real-Time Monitoring and Reporting: With Khenda’s customizable dashboards, you gain instant access to real-time production data. Monitor machine performance and operator efficiency with no delays, allowing for faster, more informed decisions.
Comprehensive Data Tracking with Khenda
With Khenda’s AI-driven system, you gain access to a wide range of real-time data from your production floor, all presented in customizable dashboards and detailed reports. Here are some examples of the key insights you can gather:
Processing Time: Total hours spent on processing during a selected time period.
Labor Utilization: Number of operators working.
Product Flow: Total number of units produced and passed through the line.
Production Tempo: The speed at which products are manufactured.
Defect Rates: Calculations on waste and defective products, helping you understand your quality metrics.
Preparation Times: Time taken to switch from producing one product to another.
Downtime Analysis: Duration of machine stoppages, including the specific machines responsible for the delays.
Why This Matters for OEE
By leveraging Khenda’s AI-driven solution, manufacturers can gather the critical data needed to calculate Overall Equipment Effectiveness (OEE) without dealing with the complexities of traditional integrations.
Availability: Track machine uptime and downtime with precision, using AI to detect stoppages and identify causes instantly.
Performance: Measure production speed automatically and compare them against expected production rates for a clearer view of performance.
Quality: Automatically track the number of units entering the production line and measure output against expected levels.
Conclusion
With Khenda’s AI-powered system, you can transform your production data into tangible financial gains. By using your existing cameras, Khenda tracks processing times, labor utilization, production flow, and defect rates, giving you real-time insights that help optimize operations without the need for expensive infrastructure.
The result? Lower operational costs, reduced downtime, and shortened preparation times—all leading to higher productivity and profitability. By assessing quality metrics, and enabling data-driven decisions for production planning, Khenda helps you optimize resource allocation and make smarter, faster decisions that directly impact your bottom line.
Ready to Overcome These Challenges?
Take control of your production efficiency with real-time data insights. See how our solution can simplify data collection and boost your operational performance.
Request a Demo and explore the full capabilities of our product on the Vision MES page.