The challenge was the considerable costs associated with machine downtime at the plant. The longer it took to call for help during the downtime, the more money the customer lost. Critical to improving production and increasing efficiency is reliable, real-time information on the status of tasks that often span several days.

The biggest challenges that arise in production facility processes are:

• Lost downtime,
• communication problems between teams and employees,
• excessive and unstructured data, often in paper form,
• lack of up-to-date information,
• lack of prediction of breakdowns and other events,
• lack of control over OEE indicators and KPIs.
• The goal was to eliminate or reduce all of these problems.

The power lies in simplicity. Our system is intentionally designed to achieve success by minimising losses and streamlining processes.
The project was carried out in the individual phases:

• Phase I - AndonCloud: The AndonCloud software was successfully introduced within two weeks. Using artificial intelligence and cloud computing, AndonCloud predicts the risk of failures and errors, diagnoses anomalies and forecasts performance indicators.
• Phase II - PDA SOFTWARE (Production Data Acquisition): In response to the customer's request for a solution to monitor the status of certain tasks within a production element, a practical tool was introduced - a display equipped with a code scanner. This scanner allows users to enter the status of the task, such as "start", "pause" and "finish", based on the task card. This allows all employees involved to follow the progress of the process directly from the displays. Thanks to this real-time transparency, operators, team leaders and production managers can see at any time what stage a particular element is at. This in turn allows them to prepare the workstations for the arrival of a particular element, which ultimately increases the overall efficiency of working with the element and ensures better control of the material flow. As the collaboration continues, the company is further developing the PDA software to adapt it to other needs.
• Phase III - Crane Reservation System: After the initial implementation, the customer, who was satisfied with the collaboration, reported another need. He needed a tool for booking and planning the use of cranes, whose availability was a bottleneck in several production processes. A solution was delivered that allowed the customer to plan the use of the crane for a specific task, supplemented by operators in advance. This solution led to satisfactory results and was implemented by the customer.
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• Efficient production planning and KPIs in real time
  The visualisation of production plans and real-time KPIs (Key Performance Indicators) plays a crucial role in quickly identifying areas that need to be optimised. Both employees and managers can track daily progress within specific roles.
• Rationalised production line through digitalisation
  The transition from paper documentation to an automated system for capturing production data improves accuracy and authenticity. This digital transformation provides a real-time overview of the entire production process, simplifying monitoring and ensuring precision.
• Fast response to maintenance
  With instant voice, SMS or email notifications, maintenance services can respond immediately. The system records station activity and current production data is accessible from any computer, facilitating a quick response.
• Monitoring employee performance
  We empower employees by quantifying their impact on the overall factory goal. The automatic generation of OEE (Overall Equipment Effectiveness) reports and the real-time display of key parameters on monitors ensure continuous performance monitoring.
• Other improvements:
  • Digitalisation of the production line,
  • improvement of communication within the production team,
  • the ability to analyse production parameters: Efficiency, availability, quality,
  • Organisation of information flow,
  • Monitoring of elements of the production process,
  • Access to information on task status,
  • Visibility of important information for many people in one place,
  • Control of material flow,
  • Rationalisation of the process by preparing positions for picking up elements