The system says it is finished. The floor says otherwise
Every plant runs two records of the same production, both maintained honestly, and reconciles them once a month. That delay is where the variance comes from.
- ERP
- shop floor
- data latency
Blog
Why the system and the floor disagree, why machine data never reaches a decision, and why nothing we build will ever write to a machine.
Your machines have been talking for years
Most plants are already instrumented. The data goes to maintenance and stops there, so the plant is well measured for engineering and blind for planning.
- OPC UA
- SCADA
- machine data
Traceability for an audit is not traceability for a recall
Most plants can produce the records an auditor asks for. Far fewer can answer which shipped units contain a suspect batch, before the second phone call arrives.
- traceability
- genealogy
- recall
A promise date from standard times is a guess with a decimal point
Standard times describe an operation running well with nothing going wrong. Schedules built on them are optimistic by a factor nobody measures and everybody absorbs.
- scheduling
- throughput
- promise dates
Nothing we build touches the control path
Reading from a machine is an integration problem. Writing to one is a safety problem, and they should never be presented as two settings of the same feature.
- functional safety
- OT
- boundaries