Unlocking Manufacturing Efficiency Potential

Every move should deliver the maximum return at minimal effort.

Maximizing the efficiency of production operations is the most important objective within a manufacturing plant. The teams of engineers within each company are responsible for ensuring that production levels and product quality improve day by day. Today there are already technologies, which implemented in your company that would act as catalysts, supporting people who make decisions about actions to achieve productive efficiency.

In this era in which digital data abounds about machine operation, tooling, demand, and equipment, a great opportunity arises to revolutionize efficiency in manufacturing plants. For years, executive decisions about improvements in the production environment, about the investment in the necessary installed capacity, the forecast of material requirements or the specialized attention of some recurrent failure, have been based on exhaustive analyses carried out by several engineers inside the plant that could take several months to develop. The decision that had to be taken to correct a certain course in the operations waited months to see the light, months of lost efficiency, and that, since time does not return, it will be impossible to recover.

In terms of production, the ideal state would be to maintain 100% efficiency throughout the entire operating time. It should be noted that it is not possible to reach a state of efficiency beyond 100%. No more than 100% availability, no more than 100% quality, no more than 100% performance. Therefore, every day in the industry is subject to potential loss, every interruption of production, every slow cycle, and every cycle of low quality becomes a loss, every decision not taken to correct a problem is generating a loss that can never be recovered.
Every move should deliver the maximum return at minimal effort.

As an example, if in our plant we maintain an OEE of 85% and one day the level reached becomes 80%, that 5% cannot be recovered even if the next day we have a level of 85% again. In any case, as opposed to 100%, we are in a constant state of 15% loss. An option, in this case, would be to budget considering the 15% loss, but the vertiginous and fast competition that exists in the sector could make us lose a client just for cost decisions, and therefore it is not a viable option. In this scenario, the optimum is to control what is in our hands, increase the level of OEE to a new level of permanence closer to 100%, is not an easy task, but if you do not have the right data and analysis tools, surely becomes an impossible task.

“That 1% of efficiency that was lost that day is a 1% loss that will never be recovered.”

Information technology currently allows us to obtain large amounts of data on operations. Speaking of digital data, a manufacturing company with plastic injection molding processes generates millions of data daily. Hardly a human mind will be able to analyze all the data that is generated in just one hour of production in order to make the right decision at the right time. Therefore, in the search for productive efficiency, it is essential to have technologies that allow us to analyze information not only exhaustively but also quickly. Executive decisions based on manufacturing data do not have to take months.

At Logykopt we are committed to helping manufacturing companies achieve maximum production efficiency. We seek to free companies from all the obstacles that prevent them from achieving this ultimate goal. That is why we have developed specific algorithmic intelligence technology to analyze large and complex data structures, to analyze past production, and make improvement decisions, and we have gone even further to forecast future production. This technology is available to injection molding companies through our SCHEMA® platform.

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Our platform is based on three fundamental pillars in manufacturing: Scheduling, Execution, and Control. For each of these pillars, we have designed and developed algorithmic technology so that it is ready to be used just by registering your company on our website

Production scheduling has specific combinatorial analysis methods for molders. All an optimization engine designed to schedule the highest production in the shortest time possible considering the finite capacity and production constraints.

The Production Execution absorbs all the information contained in the schedule and visually disposes it to the production team to coordinate the activities in an effective way. To deploy in the plant the complete production schedule, and that all the personnel knows the indicators of production, the quantities in process and finished they help to that jointly all the goals of production are reached.

Production Control is based on analytical algorithms that allow differential calculation of OEE (Overall Equipment Effectiveness) based on actual production data, visualization of specific data on actions and production elements, as well as receiving performance observations. All united in a single platform to make the right decisions at the right time for both the present and the future.

Thanks to the combination of these three fundamental pillars, SCHEMA® has become the platform on which planning and production teams at injection molding plants collaborate and achieve high efficiency, high-quality, and continuous operations.

Alejandro Ibarra — CEO 
We are the creators of SCHEMA: the production scheduling, execution and control SaaS platform for manufacturing companies to optimize in-plant operations.