Solution

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Equipment Management

Equipment inspections and maintenance plans are managed by hand or in ExcelEquipment breaks down often and we are busy with reactive repairsWe do not know why or how long equipment stops (downtime and causes)We can only check real-time equipment status by going to the shop floorRepair history and consumable spare parts are not managed systematically

Quality Management

We trace the cause of defects only after they have occurredIt is hard to link and analyze equipment conditions or data at the time of a defectQuality inspection results are recorded separately on paper or in ExcelIt is hard to see defect frequency by type or meaningful trends at a glanceThe same quality problems recur without managed preventive measures

Energy Management

We cannot see actual power usage by equipment or lineWe cannot tell which equipment or process drives up electricity costsIt is hard to predict or prepare for power peaks (maximum load)Calculating energy efficiency per unit of output is complicatedEven with energy-saving efforts, it is hard to prove the actual effect with data

Production Management

Actual production results often deviate from the original production planWe cannot see in real time how far each job has progressedWorkers write production logs by hand or compile them in Excel before leavingIt is hard to total same-day production results by item or worker right awayIt is hard to find bottleneck processes or causes of delays in production

Production Planning

Production planning depends entirely on the experience and know-how of specific staffRescheduling everything for urgent orders or order changes takes a long timePlanning manually in Excel often leads to formula errors or missing dataDaily work orders and weekly/monthly mid- to long-term plans are not linkedIn high-mix, low-volume production, it is hard to find the sequence that minimizes changeover time

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