Metalworking is one of the original forms of manufacturing; it’s what turned raw materials into the tools that helped us advance technologically and build civilization as we know it. In today’s era of full industrialization and increasing digitalization, metalworking is no longer just processes and techniques to shape metal into parts and components — it’s a high-tech and data-driven operation.
Utilizing manufacturing data on the shop floor is key to not only staying ahead of the curve, but also increasing efficiency, improving quality, and reducing costs. It begins by first understanding exactly what data you need to collect, and then how to best use it to improve your operation.
The Manufacturing Data That Matters
Manufacturing data encompasses a wide range of information collected throughout a metalworking facility and its operation; it’s integral for tracking, analyzing, and optimizing workflows and outcomes. This data is gathered through a variety of tools and mechanisms, including machine-level sensors, IIOT devices throughout a facility, mobile app, and more. You also need to invest in software like enterprise resource planning (ERP) platforms or other systems (depending on the scale of your company) to store, visualize, and analyze the data you collect.
But what kind of manufacturing data should you collect from your operation?
- Operational, such as machine performance, cutting fluid performance, speed, efficiency, and downtime
- Quality metrics, such as rework, scrap, and defect rates, compliance measurements, and results from quality control tests
- Inventory and supply chain metrics, including the status of raw materials, tracking works-in-progress, and the current inventory of finished goods
- Customer data, and records of customer interactions and feedback
- Environmental data, such as waste generation and scrap rates.
Robert Pawlicki, Vice President of Business Systems and Cyber Security at Master Fluid Solutions, asserts: “[Some of] the most important data revolves around metalworking fluid. Information on fluid concentration in the sump, pH, and conductivity can be used to control the fluids being used and make sure that operations are running properly, leading to less down time, better quality in production, improved shop environment, and better cost control.”
Why You Need Manufacturing Data
Leveraging the right manufacturing data for deeper insight allows you to enhance your day-to-day operations, which can cascade into significant improvements over the course of a year, and beyond. Some benefits include:
Predictive Maintenance
Collecting machine performance and other operational data makes it possible to predict when machinery might need servicing before it fails. Scheduling repairs and maintenance at optimal times — rather than reacting to unexpected breakdowns after they happen — significantly reduces downtime. This proactive approach to maintenance often prevents expensive repairs and prolongs equipment life, as well as improves production reliability.
Streamlined Cutting Fluid Maintenance
Similarly, monitoring fluid metrics like current sump conditions, pH, concentration, and consumption rates makes it easy to perform sump top-ups, as well as predict the best times for fluid changeouts and sump cleanings. This ensures your cutting fluid always performs at peak efficiency, reducing tool wear and improving part quality, while minimizing waste and downtime associated with fluid management. This data-driven approach to cutting fluid maintenance ensures optimal machine performance while improving cost efficiency.
Stronger Quality Assurance
Tracking quality data throughout the production process can help you detect and correct part defects early, reducing scrap rates as well as the overall impact of rework and finishing. Being proactive about quality control minimizes disruption, making your production line more efficient and reducing waste. Strengthened quality assurance can contribute to increased customer satisfaction and retention.
Process Optimization
Leveraging manufacturing data effectively allows you to significantly reduce cycle times and increase throughput, not only lowering operational costs by minimizing waste of materials and labor, but also improving product quality and consistency. Removing bottlenecks also increases the overall speed of production, helping you meet customer demands more effectively and your operation become more agile and competitive in the market.
More Impactful Decision-Making
Tracking manufacturing data enables more informed decision-making throughout your operation, whether it’s choosing to scale up or down based on demand forecasts and efficiency metrics, identifying the best opportunities for market expansion, or optimizing resource allocation by ensuring materials, labor, and capital are used as efficiently as possible. Collecting and analyzing manufacturing data lays the foundation for a more holistic approach to decision-making, ultimately enhancing your competitive edge and improving adaptability in a rapidly changing industry landscape.
Optimizing Operations: Down to the Last Drop of Cutting Fluid
Much like selecting the right metalworking fluid and maintaining it for optimal performance, continuously collecting and analyzing manufacturing data can improve efficiency and cost effectiveness throughout your operation. Predictive maintenance, enhanced quality, and optimized processes are just some areas where you’ll realize benefits.
Of course, collecting even small amounts of manufacturing data can be overwhelming if you haven’t begun your digital transformation yet, but it’s important to start somewhere. Initially, “customers collect data that they understand and can utilize immediately,” explains Pawlicki. “We train our distributors and customers on which pieces of data are likely to help them on a daily basis.”
Working with experts is critical to establishing a manufacturing data collection program and maximizing its impact on your operation. Implementing cutting fluid data collection is a great way for companies to begin the journey.
Want expert help with identifying the right fluid data collection processes for your operation? Schedule a site visit to learn more about different cutting fluid monitoring solutions and how they can streamline your business.
