During the ongoing process of production optimisation, every company eventually encounters an obstacle that seems impossible to overcome.
Perhaps ready-made systems such as MES and WMS have already been implemented and the entire process analysed and optimised using Lean, 5S and so on. Managers and engineers are then faced with the challenge of how to further improve production efficiency.
A good place to start such an analysis is by checking the current state of production:
- What is our current level of efficiency (OEE)?
- How much production time is lost to unplanned downtime?
- What is the current average response time to information about downtime? Why is this the case?
- Which problems are most frequently reported by production employees?
While it is sufficient to conduct a few interviews with employees to determine the most frequently reported problems, it is difficult to determine the other indicators in the same way.
In such cases, it is worth using a tool such as Vorne XL, which takes just one day to install and starts collecting data immediately.
How does the Vorne XL system support reporting and improve production efficiency?
In short, the Vorne XL810 is an industrial visual production monitoring system combining an LED display, a built-in IIoT engine and advanced real-time reporting software.
By connecting a scanner, operators can indicate the reasons for line/machine stoppages. Installation is straightforward – you only need 1–2 sensors and an Ethernet connection. The system can also be integrated with external MES/ERP systems or databases.
What happens once the system is connected?
Once the sensors (e.g. a production counter, which provides information about line stoppages) and the network are connected, the XL810 starts collecting production data continuously.
Operators receive clear information directly on the Andon board, including process status, status duration, event responses, production targets and order status.
In addition, the system displays messages in Polish and enables employees to record the causes of downtime using a code scanner rather than manual entry. This increases both accuracy and staff engagement.
Start collecting reliable data and work on improving your metrics!
Case study: Unplanned downtime reduced by 92%.
‘Before connecting the boards to the line, we often recorded unplanned downtime of over 120 minutes per shift. Now that operators can see the downtime, they respond much faster and we have reduced it to just 10 or 12 minutes per shift,’ said the line manager at an international glass manufacturing company in Dabrowa Gornicza, Poland.
Case study: 12% increase in productivity
“After installing one board, we saw an increase in production from 1,800 to approximately 2,200 items per shift in the first two weeks after implementation,” said the Lean Manufacturing Coordinator in the automotive industry in Boleslawiec, Poland.
Case study: 22% increase in OEE
“To date, we have achieved a 22% improvement in OEE, and XL is an integral part of our production improvement process. Knowing the status of all our lines in real time enables us to solve problems immediately” – Department Manager, Personal Protective Equipment Manufacturer, Wroclaw (PL)
How else are companies using this system? An example of Vorne XL implementation in a production plant:
In the Totem digital printing house, a modern factory, this is yet another implementation of the Vorne XL system, preceded by a 60-day pilot of the solution.
The Vorne XL system helps Totem to manage production more effectively and improve processes by:
- monitoring the achievement of production targets in real time;
- recording and analysing unplanned downtime and the most frequent line failures.
A few technical curiosities:
- An industrial graphic display keeps the production line operator informed about the status of the production order.
- The operator uses a barcode reader to enter the product/order name and the reason for the downtime.
- Signals collected directly from the production line using photocells are sent to the Vorne XL system, which uses them to determine the number of bound books and identify any shortages, as well as establishing the machine’s operating status.
- The board is connected to the company’s LAN, enabling the analysis of collected data to be accessed via a web browser.
- Installing and configuring the board took about three hours without stopping the production line.
One board, many possibilities!
The XL810 contains a built-in web server and generates ongoing reports, which are accessible to all users on the network without the need to install any software. Ready-made reports are available: OEE, TEEP, downtime, loss cause analysis, production timeline, work efficiency, rejects and format changes. It also offers the ability to create your own templates or dashboards and export data to Excel or SQL.
You can add comments to any events, track reasons and report performance by team, shift or order. Access to historical data allows you to identify trends and areas for optimisation, even from years ago.
The firmware supports automatic email/SMS alerts, labour efficiency tracking and the easier reporting of errors or production events.
Why implement the Vorne XL810 production optimisation system?
- It can be implemented quickly and at low cost: The device is ready to use within an hour — all you need are sensors and a network. No additional applications or PLC modifications are required. There is a fixed, one-time fee with no subscription or licence costs, and free software updates and a hardware warranty are included.
- Immediate increase in productivity (OEE): Companies report an increase in OEE of between 14% and 22% as a result of using the Vorne XL810. For example, a reduction in downtime of up to seven hours over three weeks translates into an additional four weeks of production availability per year.
- Reduction of downtime and faster response: The system detects operating conditions, downtime and product changes in real time. Visual alarms allow operators to respond immediately. In addition, QR codes and comments support the analysis of the causes of downtime.
- Operator engagement and visual communication: The board transparently displays production targets, status information and performance results for operators. This increases their awareness and motivation to work towards production efficiency.
- Flexible reporting and online access: Current and historical data, export options, dashboard customisation and data analysis are all immediately available via a browser. This facilitates continuous improvement without the need for unnecessary printouts or manual summaries.
- System integration and expansion options: Vorne XL is designed to work with almost any PLC, MES or ERP system. It can be integrated with any process using an API interface or available integration solutions. Vorne is fully scalable: connecting performance monitoring of additional lines simply involves implementing additional boards. Over time, the scanner can be replaced with full automation (e.g. a PLC) or exchanged for a touch panel application.
