Streamline your workflows
Gain a deep understanding of your operations, identify patterns, predict outcomes, and make data-driven decisions that drive efficiency and productivity.
Simple solutions to common problems
Unlock the full potential of your shop floor by connecting every aspect to measurable access points. From operators loading materials to machines tracking turns per second, Prophecy IoT® is here to capture and harness the valuable data already being generated. With our powerful data collection capabilities, you can gain real-time visibility into the intricacies of your operations.
No more missing out on vital insights – now you can witness the pulse of your shop floor in real time, empowering you to make data-driven decisions and drive continuous improvement throughout your manufacturing processes.
The shop floor
Human Machine Interface (HMI)
In the factory environment, the Human Machine Interface (HMI) plays a crucial role. It is the interface where your workers interact with machine data that is consolidated into a single display. Our HMI provides a simplified yet highly intelligent and experience for the workers. It combines information on one screen that is needed by the operator to produce a part to specification. The information presented or actions taken on the interface is intelligent in that it can vary by production order or part. Example, if the work order requires setup, quality check or measurement, etc. then the operator is prompted for action.
With Prophecy IoT®, the HMI becomes the operators gateway to a simplified smart experience that empowers your workforce with simple limited required interaction.
Human Interface (HI)
Sometimes, there are scenarios where there may not be a sensor or machine involved at all, but still, information is necessary to support operators in assembly or manual processes. In such cases, our Human Interface solution comes into play. It allows operators to access simple information relevant to their tasks with ease. By implementing a straightforward button-click approach, our Human Interface automates processes, eliminating the need for TIME CONSUMING manual data input just to drive accounting transactions. Prophecy IoT® simplifies complex tasks and empowers operators to focus on value-added activities while leveraging the power of automation.
Andon Boards
Prophecy IoT® incorporates Andon boards as a powerful tool to enhance real-time visibility and communication within manufacturing environments. Andon boards are large displays strategically placed on the shop floor, providing instant visual feedback on the status of production processes and highlighting any abnormalities or issues that require attention.
There are several ways Prophecy IoT® utilizes Andon boards:
- Real-time status updates: Andon boards enable real-time monitoring of key performance indicators (KPIs) and critical information, allowing operators and managers to quickly assess the current state of operations. This instant visibility helps in identifying bottlenecks, production delays, or quality issues promptly.
- Immediate issue recognition: With Andon boards, any abnormalities or manufacturing problems can be visually highlighted through cues such as flashing lights, color changes, or symbols. This allows teams or operators to hit production and shift targets, reduce scrap, track late jobs, etc. all to maximize production output.
- Improved communication and collaboration: Andon boards serve as a centralized communication platform, providing a common visual reference for the entire team. Operators, supervisors, and managers can quickly identify critical bottlenecks and resource problems. For example, a detected machine down condition can display on the maintenance, team, operator, and supervisor displays in real time if a down time situation occurs. This allows teams to address issues, collaborate on problem-solving, and share important updates or alerts in real-time.
- Continuous improvement and accountability: Andon boards promote a culture of continuous improvement by fostering transparency and accountability across the entire factory. By making performance data and problem areas visible to the entire workforce, it encourages engagement, accountability, and facilitates ongoing process optimization.
By leveraging Andon boards, Prophecy IoT® enhances communication, promotes operational efficiency, and empowers teams to proactively respond to challenges and drive continuous improvement in manufacturing environments.
The Manufacturing Challenge
Productivity Killers
- Equipment Issues
- Process Issues
- Idle & Micro Stops
- Material Issues
- Mfg. / Assembly Speed
- Reduced Yield (scrap)
Prophecy IoT® Solution
- Alerts & Alarms
- ERP Interoperability
- Operator Engagement
- Andons & Dashboards
- Aggregations
- Process Alarms
Are your people and machines at their targeted output levels? The answer is probably no. All manufacturers deal with these issues. These issues stem from the expected and unexpected. Expected things are those that limit output but are anticipated like preventative maintenance, planned scrap, meetings, workers on leave, shift clean up, etc. The unexpected is where real havoc takes place and it’s things like machine breakdown, waiting on material, scrap, supervisor questions, long operator breaks, and abnormal extended setup or run times.
Prophecy IoT® is specifically designed to address these major challenges and issues that impact manufactures. Here’s how.
Prophecy IoT® helps mitigate these losses:
Loss 1:
Equipment Issues
Prophecy IoT® Solution
Prophecy monitors machine performance in real-time, detecting abnormalities and potential failures before they cause unplanned downtime. With predictive maintenance capabilities, it enables proactive maintenance scheduling, minimizing equipment breakdowns and maximizing uptime.
Loss 2:
Process Issues
Prophecy IoT® Solution
By providing real-time data to operators on things like setup, quality, drawing specs, work instructions, and changeover processes, Prophecy IoT® helps to simplify the operators experience, reduce scrap, reduce wait time for materials, engage supervisors when needed without leaving the station. It enables production teams to track and analyze setup times, run times vs. plan, micro stops, scrap & defects, etc. Thus, identifying opportunities for increasing overall equipment effectiveness (OEE).
Loss 3:
Idle & Micro Stops
Prophecy IoT® Solution
The Prophecy IoT® living network is a game changer in detecting why production is not producing to expected levels. Idle time and unexpected production stops can kill productivity. Prophecy impacts this by detecting and collecting in real time the root cause information that is causing the stop. Most systems have no ability to detect or collect information around this issue due to the large input requirements on the operators. Also, most systems have no transaction for “Waiting on Material” for example. With a simple button push the operator can indicate the stop reason and send alerts to material handling. Prophecy IoT® gives you ability to get to the root causes of all these small stops and idle situation thus increasing production efficiency.
Loss 4:
Manufacturing / Assembly Speed
Prophecy IoT® Solution
Prophecy IoT® not only captures real-time production data and performance metrics, it also compares that information to the expected plan time. Information without an expected outcome has very little value to manufacturing. Speed losses come in many forms like, unexpected scrap, machine down, worker stops, waiting on material, quality checks, paperwork, etc. Prophecy helps identify speed losses and provides insights for process optimization, ensuring maximum throughput and efficient production cycles.
Loss 5:
Reduced Yield
Prophecy IoT® Solution
Prophecy IoT® provides depth and visibility into the manufacturing process, capturing data on production yield and identifying potential yield losses. Prophecy IoT® enables proactive quality monitoring and defect detection which means yield issues can be detected, measured, and categorized in real time. This is done by several methods including machine, micrometer, camera, and operator input. By analyzing this information in real time against a spec or quality test plan operators or quality teams members know in real time if a machine or process is out of control. Root cause information is critical for making improvements in this area to improve overall production efficiency.
Real time living network defined
If Prophecy IoT® detects an operators button push, machine fault, or any relevant data from the living network, it immediately generates the necessary notifications. These notifications can be sent via text message or email, directly to the operator’s screen, supervisor’s dashboard, or displayed on TVs and Andon boards, ensuring that everyone is informed.
Prophecy IoT® offers seamless integration with your ERP system’s alert system. This means that important notifications can be automatically forwarded to the alert system within your ERP, ensuring that relevant personnel are promptly informed, or process approvals executed.
Real time living network defined
If Prophecy IoT® detects a operators button push, machine fault, or any relevant data from the living network, it immediately generates the necessary notifications. These notifications can be sent via text message or email, directly to the operator’s screen, supervisor’s dashboard, or displayed on TVs and Andon boards, ensuring that everyone is informed.
Furthermore, Prophecy IoT® offers seamless integration with your ERP system’s alert system. This means that important notifications can be automatically forwarded to the alert system within your ERP, ensuring that relevant personnel are promptly informed, or process approvals executed.
Digging into RCA (Root Cause Analysis)
Prophecy IoT® allows for drill-down analysis, enabling users to dive deeper into the data and gain detailed insights. For instance, in the case of maintenance requirements, Prophecy IoT® can automatically create maintenance tickets within the ERP system. These maintenance tickets are instantly communicated to the maintenance team, appearing on their mobile devices if you are utilizing the maintenance application. This streamlines the maintenance process, ensuring timely responses and facilitating effective maintenance management.
Unlock the power of Prophecy IoT® and take control of your business operations
At Prophecy IoT®, we recognize the inherent connections between the environment, machines, and all individuals involved in the manufacturing process. We understand that these interconnected elements contribute to the success of a factory, enterprise, and overall production. By harnessing the power of these connections, we aim to enhance manufacturing capabilities across all verticals.
Our primary objective is to optimize communication and collaboration, enabling streamlined operations and fostering greater efficiency throughout the entire manufacturing ecosystem.