Manufacturing

LEVERAGING PLANT COMMUNICATIONS TO SLASH DOWNTIME AND SPEED RESPONSE TIME

SHORTER LEAD TIMES. LOWER COSTS. HIGHER EXPECTATIONS.

Manufacturers are feeling the heat to hit their production targets in an increasingly competitive global market. To maintain their edge and maximize their profits, they’ve made operational efficiency a top priority. Yet in some heavy industrial segments, as much as 30 to 40 percent of profits can be lost annually due to unplanned downtime.1 Add in the 10 million skilled manufacturing jobs that are unfilled worldwide, and it’s even tougher to ensure peak efficiency and productivity.2 In today’s aggressive marketplace, there’s no room for continual delays and costly disruptions to production.

Whether they’re managing a single food processing facility or a string of multinational automotive plants, manufacturers are looking for new ways to improve performance, increase safety, optimize resources and run their operation smoothly.

HOW CAN MANUFACTURING COMPANIES IMPROVE PLANT PERFORMANCE – ESPECIALLY AS THEY ARE BEING PRESSED TO EXCEED HIGHER PRODUCTION TARGETS, DRIVE DOWN COSTS AND SHORTEN LEAD TIMES?

DOWNTIME IS AN EVER-PRESENT AND EXPENSIVE THREAT

Manufacturers know that downtime is one of the greatest impediments to plant performance. A stalled production line not only upsets workflow, it can jeopardize customer relationships. Equipment failure - from machinery that malfunctions to assets that break down as they age – causes expensive disruptions. The longer it takes plant personnel to respond and repair equipment, the more damaging the interruption. What’s more, systems that are not at full speed create a domino effect that can result in missed deadlines, lost revenues and disappointed customers.

When downtime occurs, any delays in communication are costly. If workers don’t have access to vital information or can only find it at a fixed work station, downtime will be prolonged. And if they must rely on additional personnel to handle a situation or are stretched thin as they cover a larger area of the plant, their ability to react quickly and make informed decisions is compromised.

Downtime events create higher safety risks and the potential for worker injury, too. Real-time communication helps mitigate that risk. Devices such as two-way radios have been effectively used in plants for years to coordinate response and improve employee safety.

EXPEDITING THE RIGHT INFORMATION TO THE RIGHT TEAM

What can plant management do to minimize costs and delays and drastically reduce downtime? Alert personnel instantly so response time is accelerated and problems rapidly resolved? Connect employees seamlessly and safely so they can coordinate and collaborate across the floor, the facility and the enterprise?

What many manufacturers may not realize is that while the threat of downtime is ever-present, they can prevent it from happening by being proactive. By giving employees the information they need where and when they need it, management can improve their ability to be informed and act intelligently, particularly as customer, regulatory and operational demands ratchet up.

Traditional systems, such as overhead paging, no longer meet the evolving demands of manufacturers. Rather than relaying the right information to the right team, paging systems blast out the same message to everyone. Radios, which were primarily used for safety, security and dispatch, have evolved. Today they are used by operators, technicians, material handlers and more. Radios integrate voice and data to link people to each other, people to machines, machines to people, and machines to machines.

MAKING THE CRITICAL SHIFT TO INTEGRATED VOICE AND DATA

Fortunately, innovative technology solutions are consolidating communications onto a common platform. Manufacturers, large and small, are making the shift to integration of voice and data in their facilities. Now employees with different communication needs – from task-based functions to supervisory duties – can seamlessly interact together.

According to a recent Motorola Manufacturing Barometer survey, two-way radios are deployed in three of every five manufacturing enterprises. Plant managers are using ultra-thin, ultra-light portable radios to coordinate tasks, send texts and access other business applications. Line workers are connecting instantly in their noisy environment using two-way portables with crystal clear voice or two-way radios with integrated Bluetooth® along with wireless accessories and Noise - cancelling headsets. Technicians are being automatically alerted via work ticket software on their radios as to which equipment is malfunctioning or which equipment needs to be inspected to ensure compliance with new predictive or conditions-based maintenance plans.

Having multi-function devices on an integrated platform can help manufacturing companies minimize overall communications costs by enabling workers to reach one another instantly – even when they have significantly different communication needs. By doing this, they eliminate the need to over-equip employees who only require a certain functionality.

ACHIEVING GREATER GAINS WITH PLANT COMMUNICATIONS

Developing and deploying an integrated plant communications platform delivers significant benefits to manufacturers, effectively ‘leaning’ the enterprise and ramping up productivity and efficiency. These benefits include:

  • Cutting Capital and Operating Costs
  • Optimizing Employee Communication
  • Increasing Employee Productivity
  • Improving Plant Productivity
  • Making Better Decisions
  • Protecting Existing Investments
  • Enhancing Data Security
  • Reducing Strain on IT Resources
  • Improving Employee Safety
  • Decreasing Up-Front Equipment Costs

TWO-WAY RADIOS

MAXIMIZING THE PRODUCTIVITY OF THE WORKFORCE

There’s virtually no corner of a manufacturing facility where using two-way radios to enhance employees’ ability to communicate together and act on real-time information doesn’t improve production throughput and productivity. Analog two-way radio systems are ideal for light industrial applications where only voice capability is required. However as you move into larger, heavy industrial use cases, the true value of digital radios begins to shine. Digital technology delivers better coverage and clearer voice – essential for noisy plants with machinery, thick internal walls, concrete barriers and obstructions. Because digital radios offer greater capacity, manufacturers can connect more workers across the expansive plant footprint and link workers in multiple sites, no matter where the location. Plus, solutions are available for alarms and alerts integration with Programmable Logic Controllers (PLCs) and to integrate with other devices and networks, delivering a full spectrum of Plant Communications options for modern manufacturers to consider and deploy.

>>>image “Two-way radio progression”

INCREASING SAFETY AND EFFICIENCY ACROSS THE FACILITY

Manufacturers are discovering that when they integrate plant communications, they resolve equipment issues and reduce unplanned downtime faster. Not only is equipment running at full speed, but employees are communicating and collaborating more efficiently. Despite disruptions that occur, they are making huge strides in meeting targets, decreasing costs and exceeding customer expectations – all while protecting their safety and enhancing their productivity.

When manufacturers choose Motorola as their technology partner, they get the proven solutions to improve operational efficiency, minimize downtime and differentiate themselves from competitors. Only Motorola has high-performance radios with integrated voice and data designed for the heavy-duty, high decibel environment, manufacturing-specific accessories, a robust wireless communications platform and an expert partner network to make it all happen.

DIGITAL RADIOS – THE ESSENTIAL TECHNOLOGY FOR STREAMLINING OPERATIONS.

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2014 MANUFACTURING STUDY

>>>image of front of PDF “MOT_DigitalTradiosManuf_042414”

TOP TEN “MUST HAVES” FOR MANUFACTURERS

MOST IMPORTANT CONSIDERATIONS FOR PLANT COMMUNICATIONS

  • 96% Reliable device with long battery life
  • 92% Accelerating resolution time
  • 91% Saving money with no usage fees
  • 90% Working in outages and emergencies
  • 90% Ruggedly built device
  • 90% Hearing clearly anywhere
  • 90% Increasing efficiency among workers
  • 88% Reaching workers anywhere
  • 85% Protecting worker safety
  • 74% Private secure communications

SMART PHONES NOT SMART FOR BUSINESS

85% Say leading cause of smart phone failure is drops.

Each failure costs:

  • 80 minutes of productivity
  • Over 2 1/2 hours of support time

Consumer devices are 3X more likely to fail than digital radios.

DOWNTIME COSTS MORE THAN MINUTES

According to leading industry researchers, unplanned downtime slashes profits by as much as 40 percent, while it undermines customer confidence and competitiveness. Downtime not only impedes workflow, it creates a cascading effect that impacts worker productivity. Consumer devices contribute to the problem – they are three times more likely to sabotage uptime than digital radios.

Eighty-five percent of enterprise leaders confirm that drops are the main reason for smart phone failures. Digital radios have been designed by Motorola Solutions to survive repeated drops from four feet onto concrete. Many manufacturers who use them know they withstand daily abuse that would destroy a consumer device.

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FIND OUT WHY TECHNOLOGY REDUCES DOWNTIME.

Discover what technology is three times less likely to fail.

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MOTOROLA ACCESSORIES

Only Motorola Original Products are performance-matched to guarantee the same high standards of quality that you enjoy with your Motorola two-way radio. When you see the Motorola Original logo on the products, you know the products are built and tested to meet the highest standards.

Work smarter with Motorola hands-free accessories. Whether they’re in the warehouse or office, on the loading dock or plant floor, your workers need hands-free tools that let them focus on the job. MOTOTRBO offers a wide variety of carry cases and belt clips for hands-free portability and a complete line of audio accessories, including a heavy-duty headset for hands-free operation and hearing protection in high-decibel factory environments.

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RESOURCES SPOTLIGHT

BROCHURES AND SPECIFICATIONS

CASE STUDIES

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