Digital Shift Analytics

Cutting costs, reducing downtime and improving production processes – companies are facing more pressure than ever to increase productivity. Körber Digital has developed a smart software solution to these issues: Digital Shift Analytics (DSA) is designed to systematically document machine downtime and radically simplify the steps involved in analyzing and troubleshooting production processes. Analyzing big data is essential for playing a role in Industry 4.0. WEPA is one company that is well prepared for the digital future: in a pilot project with DSA, the company increased its overall equipment effectiveness (OEE) by a stunning 11 percent.  

Poor documentation and analysis affect productivity

Machine operators tend to record instances of unscheduled downtime and faults manually – which often means not at all. The result: incomplete or incorrect information processing. The next shift machine operator is then in the dark as to what has already been repaired and what still needs to be done. 
Another problem in conjunction with manual documentation is that the results are far too inconsistent to be used as the basis for comprehensive analysis – and this prevents the process engineer from improving their own productivity.

Experiencing the same problems with poor documentation between shifts? We can provide the right software solution for your situation. 

Keep reading below or book a live demo and see how Digital Shift Analytics can benefit you — simply get in touch with us to arrange an online meeting here.

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An electronic logbook for identifying and eliminating weaknesses

The Digital Shift Analytics software suite by Körber Digital enhances the production process in three clear ways:

• Simple documentation for more data quality: The system helps machine operators to document problems, create shift reports and generate recommendations that operators can then implement to rectify the issue. This ensures the data is standardized, guarantees its quality, and speeds up the documentation process in general.
• Continuous monitoring for rapid reporting: Shift managers and process engineers can access the software and track the production performance of the entire site in real time. Digital Shift Analytics provides an overview of the performance of individual machines, highlights weak areas & faults and generates comprehensive reports to be consulted following a shift change. The solution can also be integrated into existing maintenance systems as required.
• Comprehensive analysis for increased productivity: Process engineers and manufacturing excellence managers can use Digital Shift Analytics to systematically analyze their machines in order to identify the cause of errors and malfunctions. A typical analysis will include automatically recorded machine data, downtimes, altered production settings, machine anomalies and operator documentation.

Best practice: production optimization software results in an 11 percent increase in OEE at WEPA

WEPA is Germany’s largest medium-sized family-run company for hygiene paper products. The company opted to employ Digital Shift Analytics to digitize its production processes. This was due to the software being designed primarily for companies with regular shift changes or continuous operations. The results have been nothing short of impressive:

• When production managers at WEPA opted to use DSA in conjunction with a test product line, the overall equipment effectiveness (OEE) increased by 11 percent. 
• Meanwhile, a closer look reveals that the product line’s general performance rose by 15 percent and its availability increased by 9 percent. 
• Despite there being only marginal room for improvement, production quality was also enhanced as a result of this shift management software.

“Our aim is to automate and streamline our complex systems, thereby reducing the manual workload for employees on our processing lines,” states Martin Krengel, CEO of WEPA. “Along the way, we are learning which functions provide genuine added value to the production chain and how we can improve shift communications. This is also enabling us to detect issues and bottlenecks in our technologies and applications at an early stage and resolve them before they become more problematic.”

Want your own company to experience WEPA’s success story?

Book a live demo and see how Digital Shift Analytics can benefit you — simply get in touch with us to arrange an online meeting here.

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Radical improvement of information processing, documentation and analysis

Digital Shift Analytics brings about an increase in productivity in two ways:

1. It streamlines the day-to-day activities performed by machine operators (e.g. machine monitoring, documenting production issues in an electronic logbook, etc.) and relies on artificial intelligence to provide useful recommendations on how to further simplify core processes.
2. Process engineers use it to monitor machine availability and performance and evaluate technical problems. Engineers can also have Digital Shift Analytics perform comparisons between the machines, track any changes in their settings and quickly prepare comprehensive shift reports that include all relevant KPIs and production parameters.

Overall, the use of Digital Shift Analytics results in substantially higher productivity in general.

Want to increase your productivity simply by using the right software? 

Book a personal live demo and see how Digital Shift Analytics can benefit you — simply get in touch with us to arrange an online meeting here.

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You are only part of Industry 4.0 when you start to analyze big data instead of simply collecting it

When employed on a production line, Digital Shift Analytics analyzes the process as a whole, identifies weak spots & faults and offers recommendations on how to optimize the current production strategy. The benefit of this data cannot be overstated, as was highlighted in a recent study by Commerzbank among medium-sized companies in Germany. 
In total, 97 percent of respondents believed big data was the future, stating that it allowed for resources to be used more effectively and work processes to be automated. However, only 8 percent confirmed that they regularly analyzed large volumes of data. Digital Shift Analytics is the ideal entry point for companies to start analyzing data, reaping the benefits and making the transition to Industry 4.0.

Want Industry 4.0 to take off within your company?

Book a personal live demo and see how Digital Shift Analytics can benefit you — simply get in touch with us to arrange an online meeting here.

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