Ever walk the shop floor and feel like something’s off, but you can’t quite put your finger on it? Machines are running, folks are working, but production’s still lagging.
That’s where digital flow audits come in, a straightforward way to use data to uncover hidden snags like long queue times or manual data reentry that kill your output. At DPS, our tools like Capacity Utilization, Downtime Tracking, Start-up Scorecard, and Lost Production Tracker shine a light on these issues.
What’s Holding Your Line Back?
Every shop deals with headaches that slow things down. Here’s what we see popping up most:
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Wasted Capacity You Can’t See
Some stations or machines just aren’t keeping up. Maybe a worker’s only hitting 5 pieces a minute when the line needs 10. Or a machine’s lagging because of bad settings or no maintenance. That’s “unidentified lost time”, capacity slipping through the cracks. -
Pesky Micro-Stoppages
Little pauses, like 30 seconds here or a minute there, add up fast. These micro-downtimes clog up the line, pile up product, and mess with your flow. Worse, a lot of them go untracked because they’re “too short” to log. -
Rough Shift Starts
The first hour of a shift can be a slog. If setups aren’t dialed in or equipment’s not ready, you’re burning time before the line even hits full speed. -
Rework and Waste
Defective parts, QA holds, or rerunning product? That’s double the machine time for half the output. Every piece you rework or scrap is stealing capacity from your line.
How DPS Tools Uncover the Problems
A digital flow audit isn’t some fancy software feature, it’s just using DPS’s data logs to get a clear picture of what’s gumming up your works. Here’s how our tools dig in:
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Capacity Utilization Charts
These break down your line’s output hourly, daily, or weekly. They show you exactly how much capacity is disappearing into “unidentified lost time.” If a station’s only cranking out 5 pieces a minute instead of 10, you’ll see it here. Same goes for machines dragging behind. -
Downtime Tracking with Pareto Charts
Our Downtime Tracker logs every stoppage and spits out simple charts showing what’s happening most often or eating up the most minutes. Got a bunch of 30-second micro-stops? You’ll spot them fast and know where to dig deeper. -
Start-up Scorecard
This tool zeros in on that critical first hour. It shows you what’s slowing down your shift starts, maybe a setup issue or a machine not tuned right, so you can fix it and hit full speed sooner. -
Lost Production Tracker
Logged hourly on the Daily Schedule Control, this tracks rework, scrap, downgrades, and QA holds. It tells you exactly how much capacity you’re losing when bad parts force you to rerun product.
Fixing the Mess: Practical Steps with DPS
Once you see the problems, DPS tools help you tackle them head-on. Here’s how to clean things up:
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Plug Capacity Leaks
Use Capacity Utilization data to spot weak spots. If a worker or machine isn’t hitting the mark (say, 5 pieces a minute instead of 10), do a quick time-and-motion study or map out your product flow to find bottlenecks. Maybe you need to tweak the line balance or add a second worker to a station. For machines, regular GEMBA Walks, where you actually go look at the equipment, can catch bad settings or maintenance issues before they tank your output. -
Squash Micro-Downtimes
Those little stoppages show up loud and clear in the Downtime Tracker’s pareto charts. If you see a bunch of short stops, pull together a team from production and maintenance to do a Root Cause Analysis. Figure out what’s tripping you up and fix it. Also, train your crew to log every stop, even the quick ones, so nothing slips through. -
Smooth Out Shift Starts
The Start-up Scorecard shows you what’s gunking up the first hour. Use it to prioritize fixes, like nailing down equipment settings or creating a pre-shift checklist to make sure everything’s ready to roll. No more limping into the day. -
Cut Down Rework and Waste
The Lost Production Tracker flags where you’re losing capacity to bad parts or reruns. Dig into the data with a Root Cause Analysis to figure out why defects are happening, maybe it’s a process issue or operator training gap. Fix it, and you’ll spend less time redoing work and more time shipping good product.
Why Digital Flow Audits Are a Game-Changer
Walking the floor is great, but it misses stuff. Digital flow audits with DPS a powerful tool from POWERS to give you X-ray vision into your line, showing you exactly where time and capacity are leaking. Catch those micro-stops, tighten up shift starts, and cut out rework, and you’re looking at a smoother-running shop with less waste and more output. It’s not magic; it’s just good data put to work.
Wrap-Up: Get Your Line Running Right
Hidden inefficiencies like long queues, micro-downtimes, or rework can tank your production without you even noticing. A digital flow audit using DPS tools like Capacity Utilization, Downtime Tracking, Start-up Scorecard, and Lost Production Tracker helps you spot the problems and fix them fast. Want to see how it works? Contact us today to learn how DPS can get your shop floor humming.
Want to build a stronger execution habit into your shop floor?
Contact DPS today and let’s get your team across the finish line, every time.