Idea Lab

Replay Analytics for Manufacturing

In manufacturing, business leaders often look at daily, weekly, or monthly performance numbers, and when they see a “bad day” they ask, “What happened?”

A new concept called Replay Analytics® can answer that question. Replay Analytics creates an animated dimension of time for past, present and future state analytics. Many business intelligence applications are designed to test hypotheses by exposing the relationships between datasets and teasing out insights. Once you’ve answered those questions, however, you need an application to monitor those important metrics in one place and to know if something is off-track without running custom reports or spending lots of time on a deep-dive. Replay Analytics delivers that insight in real-time with minimal fuss, so you spend less time collecting data and more time managing your business.

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Idea Lab - Replay Analytics for Manufacturing
Idea Lab - Factory Media Center
The Factory Media Center includes a large 90° touch interactive computer system designed to immerse users in data. It combines next generation data interaction principles with Smartboard technologies for problem solving.

Factory Media Center

Our Goal: Creating a new environment for reviewing and interacting with data on the plant floor
The Vision: Collaboration taken to a new level…

An environment on the factory floor which :

    • Immerses the operators in plant performance data
    • Integrates operators engineers, 3rd party vendors with the root cause problem solving process
    • Guarantees the use of common templates, 5 why, fishbone, etc.
    • Ensures continuous improvement activity is immediately shared, not waiting on being typed up and circulated
    • Creates total visibility, connectivity and accountability for performance across the entire business
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Advanced Andon System

“Andon” – The definition

Andon (アンドン, あんどん, 行灯) is a manufacturing term referring to a system to notify management, maintenance, and other workers of a quality or process problem. The centrepiece is a signboard incorporating signal lights to indicate which workstation has the problem. The alert can be activated manually by a worker using a pullcord or button, or may be activated automatically by the production equipment itself. The system may include a means to stop production so the issue can be corrected. Some modern alert systems incorporate audio alarms, text, or other displays.

An Andon system is one of the principal elements of the Jidoka quality-control method pioneered by Toyota as part of the Toyota Production System and therefore now part of the Lean approach. It gives the worker the ability to stop production when a defect is found, and immediately call for assistance. Common reasons for manual activation of the Andon are part shortage, defect created or found, tool malfunction, or the existence of a safety problem. Work is stopped until a solution has been found. The alerts may be logged to a database so that they can be studied as part of a continuous-improvement program.

The system typically indicates where the alert was generated, and may also provide a description of the trouble. Modern Andon systems can include text, graphics, or audio elements. Audio alerts may be done with coded tones, music with different tunes corresponding to the various alerts, or pre-recorded verbal messages. Usage of the word originated within Japanese manufacturing companies, and in English is a loanword from a Japanese word for a paper lantern.

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The Next Generation Andon System…

Idea Lab - Andon System

A combination of:

  • Large overhead plant floor displays
  • Utilization of existing Operator HMIs and plant floor terminals
  • Alerting technology using emails and SMS type messaging