A production counting is fitted with proximity sensors, namely photoelectric diffuse sensors, so that the products may be counted. When the sensor light strikes the surface of an object in front of them, it is reflected, and this is how proximity sensors detect it. This guarantees precise counting for increased effectiveness. No matter how transparent or colored the object is, proximity sensors can still recognize it with ease.
To gain useful performance insights, the firm must supply two sensors and enter data about the whole manufacturing process at the beginning and conclusion of the planned production: a total count sensor, a good count sensor, the takt time input, and the optimal cycle time input.
Lean manufacturing and production counters
Lean manufacturing, according to TechTarget, is a process that aims to maximize efficiency while reducing waste in production systems. Any item that a buyer refuses to pay for because they don’t think it offers value is considered waste. Consequently, it becomes sense to put in place a counter system that can precisely stop waste by keeping a careful eye on production efficiency. The following are included in the five lean manufacturing principles:
Reducing wasteful expenses to maximize customer value while maintaining optimal business costs
Determine waste by mapping the complete product cycle.
Optimize the takt time to avoid delays and disruptions.
Establish a production page target that is in line with demand (pull system).
Keep improving the process.
The benefits of production counters
According to the Toyota Production System, implementing a counter can assist in addressing some of the seven wastes of a lean production:
Overproduction, as the team may be informed via the display when the target number is attained
Excessive waiting or idle time is the reason counters are used to track pauses. Managers may define production pace goals for each step with the use of the counter data.
Over-processing: When the takt timer exceeds the ideal moment for the optimal outcomes, the counter display can notify users.
Defects: The majority of counters include the ability to provide a breakdown of counts, including the total and good units.
excess inventory, which is shown on the appropriate display inside the business
The significance of electronic counters
Depending on its surroundings, the counter display is adjusted for optimal visibility. Digital counter displays are also used to communicate relevant information about the activities. In both indoor and outdoor industrial facilities, the following three displays are typically used:
The anticipated number of goals
How much has already been created based on feedback from real-time counters
Stops or downtime
Time spent in production, current takt time, efficiency metrics, and good count—that is, the number of goods that passed the test and were deemed to be of high quality—can all be shown on other production counter displays.
The display is used by the production management to keep an eye on the status of the project, identify problems before they cause customer discontent or financial loss, and modify the production speed objective as necessary.
OEE Performance Management Software and production counters for maximum output
A production counter system is intended to maintain your business operations by monitoring pertinent data to assist:
Cut down on waste
Fulfill the demands and expectations of the client
Control expenses
Make inventories more efficient
Establish the ideal manufacturing speed target.
Conserve your productivity.
Factrac is an industry leader in overseeing the total equipment efficiency of your business. Your manufacturing resources’ level of use is indicated by your OEE score. Therefore, we are eager to suggest putting in place dependable production counters that may assist in elevating your manufacturing processes. Do not hesitate to contact our team of experts if you would want to learn more about how purchasing counters might help your OEE.