Navigating Production Line Obstacles with Real-Time Monitoring in Connected Equipment

Have you ever discovered an underperformance in your production capacity through data, only to find yourself having to physically visit the production line to grasp the actual situation? Even worse, there’s no one available to report the issue, leading to a delayed notification and maintenance process that escalates the time and cost spent.

What if you could streamline these processes using the real-time monitoring features of connected equipment? This article will discuss how this innovative approach can make a significant difference in three key areas of your operations.

1. Looking Back – Harnessing Data from Past Production

Conventional Monitoring

Conventionally, you may have relied on manual calculations to gather data on your production line, including: 

  • feeding time, 
  • machine production time, 
  • output of good and defective products, 
  • mold replacement time, or 
  • machine downtime.

All these variables had to be accounted for by personnel. In a high-pressure environment where one staff member might be responsible for multiple machines, the room for error becomes significant. This is why output data from machines is often used solely for evaluation, rather than as a benchmark for future production.

Real-time Monitoring

Enter the transformative power of connected equipment. This technology brings precision to data collection, acting as an additional workforce that provides real-time monitoring of all equipment and machine data, including output and production capacity. The result? Your existing staff are liberated to focus on the operation and maintenance of the machines, thus maximizing production capacity.

2. The Here and Now – On-Site Monitoring and Status Control

Conventional Monitoring

The smooth operation of your production line heavily depends on the stable performance of your machines and equipment. In conventional setups, problems are usually addressed reactively, leading to potential disruptions in your production line. However, should a technician find no serious problem, production resumes, often leading to a less-than-smooth process.

Consider the scenario of two machines: one consistently produces 30 units within an hour (one every 2 minutes); the other produces 15 units in the first 20 minutes, becomes stuck for half an hour, then resumes normal production in a rush to catch up. Although the output may be similar, unstable machines increase the burden on operators, requiring additional time for detection and maintenance and potentially leaving the root cause of equipment problems undiscovered.

Real-time Monitoring

The connected equipment system addresses these challenges head-on. Alongside recording data and providing real-time status reports, this system effectively monitors and manages machine operation status. By keeping track of past repairs, it helps you avoid repetitive maintenance and understand your machines’ fault history better. This proactive approach ensures that your machines operate normally, allowing you to schedule maintenance, report repairs promptly, and keep a close eye on the progress of your production line.

3. Looking Ahead – Predicting Future Production Capacity, Maintenance, and Optimization

Conventional Monitoring

The ultimate goal of data collection is to inform your future production plans. Conventionally, previous production data served primarily as reference values to estimate a range for future production capacity, with little deviation from past performance. This approach limited your growth potential and made it challenging to identify opportunities for improving production line capacity when faced with increased orders and congested work orders.

Real-time Monitoring

However, with connected equipment, your post data collection of each work order’s status, capacity, and output can be precisely analyzed. This includes records of defects, their causes, and frequency, allowing for a detailed evaluation of station procedures and processes’ optimization. Additionally, graphical representations of equipment utilization can help you determine whether maintenance standards should be increased based on the equipment’s actual operating time.


In summary, real-time monitoring with connected equipment delivers several significant advantages for your production line operations and management:

  1. Accurate data collection: Connected equipment provides precise data collection, enhancing your evaluation and decision-making process for future production plans.
  2. Real-time status monitoring: Connected equipment systems enable effective monitoring and management of machine operation status, reducing the burden on your operators and ensuring smooth operation of your machines.
  3. Predictive analytics for future production capacity, maintenance, and optimization: By analyzing collected data, connected equipment can help you optimize your station procedures and processes, schedule maintenance, and make informed decisions about improving your production line capacity.

By concentrating on these three key areas, you can fully harness this technology and guarantee the success of your production lines.

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