Although dealing with idle capacity is common in the industrial environment, here we are going to talk about hidden capacity, which involves a comprehensive analysis of lead times and production bottlenecks throughout the factory, and not just individual equipment. This approach allows for the identification of various improvement opportunities that go beyond simply maximizing equipment operating capacity.
Many companies focus solely on the individual efficiency of their equipment, without considering that it is possible to increase the overall equipment effectiveness (OEE) and still lose money. This can happen if the various assets of the company do not operate in complete harmony.
The system developed by COGTIVE uses technologies such as IoT, apps, and cameras to collect data and provide a comprehensive view of all processes in real-time, allowing for quick identification of possible bottlenecks. This digital approach also enables the identification of inoperative equipment, as well as the generation of reports on lead times for production orders and product holding by production line.
Another great feature is TAELOR, our Artificial Intelligence, which generates feedback through machine learning to enhance strategic decision-making and increase productivity. And the entire framework is integrated with industry ERP systems, serving the largest ERPs in the market such as SAP, TOTVS, Microsoft, Siemens, and Oracle.
One of our success stories is Ourofino Saúde Animal, one of the most traditional brands in the veterinary market, with over 30 years in the market. With COGTIVE’s shop floor solution, the company was able to increase its OEE by 29%.
At Ourofino, there was an industrial park consisting of 85 equipment whose records were manually done. This process led to occasional problems of speed and accuracy in identifying bottlenecks, production line stops, and the need for optimization of resources, line operators, and the maintenance team.
By deciding to implement digitized data collection on the shop floor, Ourofino found the ideal partner in COGTIVE. With the use of technology, the data collected on the equipment was condensed and made available in real-time dashboards, allowing for immediate monitoring through a digital productivity kanban (Flow View) on the fly.
In addition to improving its OEE by 29% and having a 360-degree view of the shop floor, Ourofino saved about 600 hours/year of its entire line operator team.
“Here at Ourofino, we always seek digital solutions to revolutionize the industry, and through the virtualization that COGTIVE provided us, we elevated our company to an even higher level, undermining the idle capacity of our shop floor,” highlights Milton Rizzo, Operations Director at Ourofino.
