In 2018, we discussed the challenges faced by plant managers, such as time-consuming activities that prevented their focus on the big picture. These included excessive meetings, unclear production losses, and a lack of real-time operational visibility. We also highlighted the potential of emerging technologies like the Industrial Internet of Things (IIoT), Big Data, and Artificial Intelligence (AI) to alleviate these issues.

Now, five years later, let’s explore how these technologies have transformed plant management.

Persistent Challenges of Plant Managers in 2018

Back in 2018, plant managers grappled with a myriad of issues that hampered their efficiency and effectiveness. From an overload of meetings and unclear production losses to the lack of real-time visibility and unpredictable job orders, the challenges seemed insurmountable. Competing priorities further compounded the complexities, making it difficult for plant managers to steer their operations towards optimal productivity.

2023 Outlook: Transformative Power of Technology

As of 2023, technological innovations have transformed  plant management. These advancements are not just tools for problem-solving but strategic assets enhancing efficiency and productivity, reflecting the evolved strategic roles of plant managers.

1. Automated Work Actions Plans

In our 2018 version, the emphasis is on the challenges faced by plant managers – managing daily operations, malfunctioning machinery, and shifting labor policies. The solution proposed, i.e., automated work action plans, is presented as a tool to help manage these challenges. It’s described as a system that collects granular data, identifies actions causing downtimes and slow cycle times, and assigns tasks automatically. 

By 2023, the description has evolved to reflect a more strategic view of automated work action plans. Instead of focusing on the problems they solve, the emphasis is now on the benefits they bring. They’re seen as a tool for increasing efficiency and productivity. The description is less about managing issues and more about optimizing processes. The benefits remain the same, but are described in a more concise manner.

Automated work action plans, pivotal in 2018 for managing daily operations and malfunctions, have evolved by 2023 into strategic tools for optimizing processes. As their roles became more strategic, the tools they used also shifted from being just problem-solving aids to strategic assets that drive growth and innovation.

Key Benefits:

• Easily prioritize tasks.
• Address issues swiftly.
• Delegate tasks automatically.

2. Integrated Smart Video for Downtime Analysis

Back in 2018, we were excited about this new thing called ‘integrated smart video’. We wrote about how it could solve the age-old problem plant managers faced: the ‘blame game’ between operators, maintenance, and quality control whenever a machine went down. 

We talked about how these videos weren’t just ordinary feeds, but ‘integrated’ ones, timestamped and connected to your manufacturing processes. This allowed you to simply point, click, review footage,  nailing down the exact moment things went wrong. Back then, this was considered cutting-edge.

We’ve come a long way since then. Integrated smart video isn’t the shiny new toy anymore; it is now  an essential tool for efficient operations. Integrated smart video, once a novel solution for identifying downtime causes, has matured into a vital tool for process optimization and employee training, reflecting its deep integration in everyday plant operations.

Key Benefits:

• Quickly identify downtime sources.
• Optimize processes through video analysis.
• Enhance employee training effectiveness.

3. Artificial Intelligence in Job Scheduling

In 2018, we were just starting to grasp the potential of artificial intelligence (AI) in job scheduling. We talked about how scheduling was often a stressful task for plant managers, and how traditional tools couldn’t account for anomalies and randomness. We were excited about AI because it promised to do just that, by considering thousands of factors simultaneously and making predictions based on past behaviors and patterns. We envisioned future job scheduling solutions as constantly learning and experimenting systems that could balance efficiency and cost-effectiveness in ways humans couldn’t.

Now, in 2023, job scheduling has been transformed by the integration of AI. Once a novel concept, has become a standard, revolutionizing job resources management with its ability to adapt and predict efficiency. They’re doing everything we hoped they would do – accounting for randomness, predicting events, and constantly learning and adapting. The focus has shifted from explaining what AI can do to highlighting the benefits it brings – efficiency and cost-effectiveness.

Key Benefits:

• Optimize equipment usage.
• Save time and money.
• Manage job resources more efficiently.

4. Cloud-Based Factory Analytics for Remote Management

In 2018, we were just starting to explore the possibilities of managing plant operations remotely using cloud-based factory analytics. We painted a picture of a future where plant managers could see their entire operation right in the palm of their hand, receiving mobile notifications about significant downtimes, slowed production, and late starts. We were excited about systems that could not only inform us when a machine goes down but also why it happened and even predict breakdowns before they occur. We dreamt of machines that could inform the right employees at the right time when issues arise, leading to highly autonomous and efficient maintenance teams.

In 2023, the language has shifted from imagining future possibilities to stating current capabilities. Cloud-based factory analytics are now commonplace and plant managers are indeed able to monitor their operations remotely. They receive real-time notifications about significant issues and have insights into the root causes. Predictive maintenance is no longer a soon-to-be-realized concept but an integral part of these systems, allowing for proactive addressing of potential breakdowns.

The ability to delegate tasks and assign escalation paths to machines is now a feature, contributing to the autonomy and efficiency of maintenance teams.

Key Benefits:

• Delegate tasks remotely.
• Decrease downtimes.
• Maintain visibility into plant operations from anywhere.

The Comprehensive Shoplogix Advantage

Shoplogix’s solutions integrate data analytics, automation, and AI, offering real-time visibility, data-driven decision making, predictive maintenance, remote management, and efficient resource utilization. . Plant managers benefit from:

Real-time Visibility: Shoplogix provides plant managers with real-time visibility into their operations, ensuring they are always well-informed about the status of production processes.

Data-Driven Decision Making: By leveraging advanced analytics, Shoplogix empowers plant managers to make data-driven decisions, allowing them to address issues promptly and optimize operations for maximum efficiency.

Predictive Maintenance: Shoplogix’s solutions go beyond reactive maintenance by incorporating predictive maintenance capabilities, allowing plant managers to anticipate and prevent machine breakdowns.

Remote Management: With cloud-based solutions, Shoplogix enables plant managers to manage their operations from anywhere, receiving instant notifications and insights into the performance of their production facilities.
Efficient Resource Management: The AI-driven capabilities of Shoplogix assist plant managers in optimizing job scheduling, ensuring efficient use of equipment and resources while minimizing costs.

The Future is Now (Again)

While these advancements may sound like a glimpse into the future, the reality is that many of these capabilities are available to plant managers today. Robust data analytics platforms empower managers to navigate their plant floors with ease, addressing issues promptly and efficiently. The increased efficiency resulting from these technologies not only saves time and resources but also allows plant managers to redirect their focus towards strategic aspects crucial for organizational success.

The future of plant management, characterized by robust data analytics and AI-driven platforms, is not a distant dream but a present reality. As we embrace these technological innovations, plant managers are well-equipped with the tools to navigate the challenges of the modern industrial environment, making more informed decisions and steering their operations towards unprecedented levels of efficiency.

The future, it seems, has arrived, and plant managers are at the forefront of this exciting revolution.