Understand
production
disruptions
Production disruptions are understood through systematic analysis of machine, process and environmental data to identify root causes and recurring issues, developing long-term solutions to minimise downtime.
GO TO APPLICATION
Analyse machines with the most disruptions
Challenge:
Without a clear overview, it is difficult to identify which machines frequently cause faults and why. This leads to recurring breakdowns and increased costs.
Benefits of WeASSIST:
- Automatic recording of all malfunctions
- Number and type of malfunctions per machine
- Categorisation according to malfunction types
- Targeted measures
Analyse the type and number of malfunctions on a machine
Challenge:
Without a clear overview of the type and frequency of machine malfunctions, their causes remain unclear, leading to recurring problems, increased downtime and production losses.
Benefits of WeASSIST:
- Automatic categorisation of all faults according to type and cause
- Identification of weak points to initiate preventive measures
- Reduced downtime and higher machine availability
Record and analyse set-up times
Challenge:
Vague or inaccurate data on setup times make optimisation difficult and cause inefficient processes.
Benefits of WeASSIST:
- Start and end times of each setup process
- Comparison between target and actual setup times
- Analysis of deviations and frequent causes of delays
Assign the right person to the most important problem area
Challenge:
When production disruptions or deviations occur, valuable minutes are lost while employees search for the problem area or do not know who is responsible. Long search and travel times exacerbate downtime and delay the solution.
Benefits of WeASSIST:
- Push notification: The responsible person is informed immediately
- Clear information about the affected machine or production site
- Immediate sharing of proposed solutions or required resources
Safety on site: Documentation of errors provides a basis for argumentation
Challenge:
Without complete documentation of errors, clear evidence for problem analysis, responsibilities and on-site discussions is missing, which makes it difficult to argue when making decisions or escalating issues.
Benefits of WeASSIST:
- Automatic recording and storage of all errors
- Clear presentation of error frequency, causes and measures
- Transparent error documentation creates security on site, supports well-founded argumentation and promotes data-based decision-making
Analyse response time to faults and shutdowns
Challenge:
Long or unclear response times to faults and shutdowns lead to avoidable production losses. Without data, there is no basis for identifying delays and optimising the process in a targeted manner.
Benefits of WeASSIST:
- Recording and analysis of the time between the occurrence of a fault and its rectification
- Identification of bottlenecks and potential for improvement in fault handling
- Optimise processes, rectify faults faster and thus increase production output
Average operating time of machines before failure
Challenge:
Without transparency regarding the average operating time of machines until a fault occurs, it is difficult to plan maintenance intervals and proactively avoid failures.
Benefits of WeASSIST:
- Recording of operating times of each machine until the next malfunction
- Identification of machines with frequent or short operating times until malfunction
- Reduction of downtime and increase of machine availability through data-based insights into operating times and malfunction patterns
Overview of disruptions with productivity loss per workplace
Challenge:
Without centralised recording and analysis, disruptions at manual workstations remain unclear, which makes optimisation more difficult and leads to recurring failures.
Benefits of WeASSIST:
- Clear overview of how often each workstation is affected
- Standardised recording and categorisation according to the type of disruption (e.g. operating error, material problems)
- Identification of trends and recurring patterns across all workstations
Call for action
systems
WeASSIST enables real-time monitoring of machines, processes and employees. This ensures efficiency, quality and safety by detecting critical deviations at an early stage and initiating immediate action. Transparent data sharing and automatic notifications minimise downtime and promote a safe working environment. This helps to proactively avoid problems and sustainably optimise production processes.
GO TO APPLICATION
Support in the event of problems at work without leaving the workplace / help at the push of a button
Challenge:
When problems arise, employees often have to leave their workplace to get help or information. This leads to delays, increased travel times and downtime.
Benefits of WeASSIST:
- Option to request support directly at the workplace at the push of a button
- Automatic notification of the responsible person or department with details of the problem
- Real-time feedback and solution support without leaving the workplace
- Reduced travel and waiting times, faster problem solving and a more efficient workflow directly at the workplace
View the status of the entire production process at any time
Challenge:
Without a centralised overview, it is difficult to quickly identify the current status of production and potential problems at individual points.
Benefits of WeASSIST:
- Status of all machines and production lines
- Live data on capacity utilisation, throughput times and downtimes
- Critical points or faults at a glance
- Quick response to problems
View the status of the entire production process from any location
Challenge:
Without centralised and location-independent access to the production status, it is not possible to monitor processes in real time, make quick decisions and intervene in good time when problems arise.
Benefits of WeASSIST:
- Access from any location and device, regardless of physical presence in the plant
- Automatic notifications in case of deviations or malfunctions
- Provision of a dashboard with real-time data on machine status, order progress and production performance
Identify and monitor bottleneck machines
Challenge:
Bottleneck machines that slow down the production flow are often only detected late. Without targeted monitoring, data is missing to analyse their performance and initiate optimisation measures.
Benefits of WeASSIST:
- Continuous monitoring of the performance of these machines in real time
- Presentation of bottlenecks and potential for improvement in dashboards and reports
- Identification of bottleneck machines by analysing production data such as utilisation, downtimes and cycle times
Monitor production to plan preventive maintenance
Challenge:
Without continuous monitoring of production, data is missing to detect wear or potential malfunctions at an early stage and to plan preventive maintenance measures.
Benefits of WeASSIST:
- Real-time monitoring of machine performance, operating times and fault patterns
- Analysis of wear indicators and automated maintenance recommendations
- Prevention of unplanned downtime, optimised maintenance cycles and longer machine service life
Increase productivity
Optimised work processes, intelligent use of resources and minimised downtime enable companies to achieve more in less time. Efficiency, prevention and technology are the keys to sustainable success.
Challenge:
Without a clear visualisation of Overall Equipment Effectiveness (OEE), inefficiencies in production cannot be quickly identified and productivity-boosting measures cannot be introduced in a targeted manner.
Benefits of WeASSIST:- Real-time visualisation of OEE values for machine availability
- Analysis of OEE deviations and identification of weak points in production
- Fast identification of production inefficiencies and the ability to take targeted measures to improve productivity and machine availability
Challenge:
Without clear comparative data, it is difficult to identify differences in performance between shifts and to make targeted optimisations.
Benefits of WeASSIST:- Comparison of the shop floor performance of each shift
- Clear insights into the causes of deviations and recommendations for action
- Successful shifts serve as a role model for other teams
Challenge:
Without historical comparisons, it is difficult to assess whether machine performance has improved or deteriorated and what trends are emerging.
Benefits with WeASSIST:- Detection of performance improvements or declines over time
- Comparison of output, runtimes, downtimes and other parameters
- Presentation of production performance at defined points in time (e.g. day, week, month, year)
Challenge:
Without a systematic recording of the number of packages packed, it is difficult to monitor production progress and efficiency. This makes it difficult to plan and analyse productivity in the packaging process.
Benefits with WeASSIST:- Automatic real-time recording of the number of packages packed
- Recording of data for a defined period (e.g. per shift or day)
- Detailed evaluations and reports for analysing packaging performance
Challenge:
Without continuous monitoring and analysis, waste in the form of resources, time and materials cannot be quickly identified and eliminated, which reduces productivity and increases costs.
Benefits of WeASSIST:- Real-time monitoring of production and storage processes to identify inefficient processes or material waste
- Analysis of sources of waste, such as idle time, production errors or unnecessary material consumption
- Reduction of waste, increase in resource efficiency and improvement of production performance through targeted process optimisation measures
Challenge:
Without detailed insights into energy consumption per unit of production, it is difficult to take targeted measures to reduce energy consumption while increasing output.
Benefits of WeASSIST:- Real-time monitoring of energy consumption in relation to production output
- Analysis of energy consumption per unit produced and identification of optimisation potential
- Reduction of energy consumption per unit of production, increase in productivity and simultaneous promotion of environmental responsibility and conservation of resources.
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