Manual production, although challenging to monitor, remains an essential process for many industrial sectors, especially in activities that require manual skills and human precision, which are still beyond the capabilities of machines.
Therefore, in order for production to maintain a standard of productivity, it is necessary to understand this process and its best practices in depth. In this article, we will explore how the industry can monitor manual production with the help of innovative technologies and we will analyze the results that effective monitoring can generate for companies in the sector.
Why have a clear view of manual production?
Manual production is predominantly controlled by human labor, which makes it difficult to access accurate data on worker performance, operating time, and bottlenecks on the production line. Therefore, it is necessary to monitor this area with a clear vision so that the company can enjoy several benefits, as you will see below.
- Identifying bottlenecks: Without specific data, it is difficult to locate where the bottlenecks are in the production process. With monitoring, it is possible to see which steps are taking the longest and where improvements can be applied;
- Productivity forecast: understanding the pace of manual production also helps in forecasting inventory and optimizing sales and delivery planning;
- Monitoring the health and well-being of workers : in environments such as cold rooms or repetitive operations, it is important to monitor workers’ rest time to avoid excessive fatigue and health risks;
- Recognition and training: identifying the most productive employees allows the company to recognize them, while workers with below-average performance can be monitored and trained according to observed needs.
Case study: monitoring manual production in chicken deboning
A food giant faced major challenges in the chicken deboning process, a predominantly manual step in its production line. The process was a bottleneck, as it made it difficult to predict productivity and identify the most efficient workers. To solve these problems, the company adopted advanced technologies with the help of Mouts TI, such as RFID, IoT-connected sensors, and AI.
The implementation of these technologies brought significant results:
- Increased forecast accuracy: After three months of use, the organization achieved 90% accuracy in productivity forecasting, which was critical for production planning and alignment with market demand;
- Productivity gain: with accurate data on worker performance, it was possible to increase productivity by 20%, identifying the best talent and optimizing operations;
- Health and safety: Technology has enabled the company to monitor employee breaks, ensuring they get adequate rest time, especially in cold environments, reducing the risk of health problems.
4 technologies to monitor manual production
Although monitoring manual production is challenging, modern technologies are already making this task more feasible. Let’s look at some of these solutions and their applications in the case mentioned above.
RFID (Radio Frequency Identification)
RFID technology allows real-time tracking of workers’ locations and production flow. In the case cited, for example, the company used RFID badges and sensors along the production line to monitor where each worker was, as well as to ensure that employees were taking recommended breaks. This technology also allows detailed analysis of employee movements, which helps to optimize the process and manage human resources.
Artificial Intelligence and Machine Learning (AI/ML)
To analyze data in real time and generate predictions, the organization used PyTorch, a machine learning library in Python, to monitor individual worker productivity. With advanced algorithms, it is possible to identify behavior patterns, predict productivity and adapt the production line to achieve optimal results. The use of AI is essential in processes that involve large volumes of data, allowing for more assertive decisions.
Line sensors and IoT
Sensors placed on scales at the end of each production line help monitor the amount of product processed. In the case of success, these sensors were integrated with the Azure IoT Edge platform, which collects data and runs algorithms to measure employee efficiency and productivity. Based on this analysis, it is possible to project future production with high precision and adjust operations according to demand.
Real-time visualization dashboards
By implementing a Qlik dashboard that updates in real time, a company can view data directly on the production line. This dashboard provides advance information on the time it takes to reach production targets, facilitating decision-making. Real-time dashboards are useful for managers to monitor progress and adjust processes – this way, production stays on track with targets.
What are the results when monitoring manual production?
Monitoring manual production generates tangible and intangible benefits for industrial companies. The main results include:
Increased efficiency and productivity
Real-time visibility allows you to make quick adjustments to your production line, correcting issues as soon as they arise. This results in more agile and productive operations, with less downtime and an optimized production pace to meet demand.
Reduction of errors and rework
Monitoring also helps identify error patterns and low productivity moments. This makes it possible to create specific training protocols, reduce rework and increase the final quality of the product.
Strategic planning with accurate data
With productivity data, the company can make production forecasts with greater accuracy, which facilitates inventory planning and reduces the risk of product shortages or excesses. This advantage is especially relevant for sectors with seasonal demands, where production adjustments need to be quick.
Improved working environment
Monitoring workers’ rest time and ensuring that breaks are taken correctly contributes to a healthier and safer work environment. Monitoring this helps prevent health problems related to fatigue and repetitive strain, which are common in intensive manual work.
Recognition and incentive for performance
Finally, monitoring allows companies to identify the best-performing employees, which makes it possible to create incentive and recognition programs. In this way, in addition to improving productivity, the company also increases employee engagement and satisfaction.
Conclusion
In short, manual production monitoring, which used to be very complex and challenging, can now be improved with the use of the right technologies. The case study presented shows that with a structured approach and the support of advanced technologies, it is possible to gain detailed insight into each step of the process and reap the benefits of effective monitoring.
Mouts TI offers tailored solutions for monitoring manual production in industry, helping companies transform data into actionable insights. Therefore, with cutting-edge technologies, we enable your company to gain productivity, safety and quality.
Contact Mouts TI and find out how to implement these solutions in your company to achieve manual production that is more connected to the strategic objectives of your business.
