Guidelines To Engage Operational and Production Efficiency During and Post-Pandemic

The manufacturing destinations at a global level, contribute to 17% of the GDP and involves about 12% of the population. Though the global impact of COVID 19 had stopped 74% of the manufacturing plants for 60 days, reopening after the lockdown is challenging. 

To avoid the spread of corona-virus and achieve operational and production efficiency, industries need to adapt following SMART ways with higher reliability and physical-distancing.

1. Organizations practice safe procedures for temperature checks to detect the health status of the workforce, modify seating for cafeteria and office areas by introducing partitions or dividers to assure physical distancing, stagger lunch-breaks to prevent get-togethers, ban entry without a face mask, limit 33% of the workforce in the plant to gradually ramp up production, and arrange for no-touch hand sanitizers at multiple locations to maintain hygiene. A pile of masks is stocked for quick usage.  

2.  A communication app for all the employees associated with the plant is used as the main form of communication. This reduces the need to remove the mask for verbal communication and encourages standard internal connectivity with the symbolic conversation. Besides, this mechanism can be remotely accessed by those working distantly. Though the production is labour-intensive, strategies involving a minimum number of workers to complete one task, or reducing the normal working hours for the plant to accommodate all the workers, or schedule the duties for alternate days to ascend the production can be drawn. Schemes to reply to employee furloughs and layoffs, to adjust production volume, to introduce a micro-break to wash hands often, and recruit a medical professional as a precautionary measure are enforced.   

3. Providing up-to-date training to the staff, regarding the safety practices and usage of the industrial asset is advisable. On the shop-floor, machinists are provided with wet-wipes and quaternary to wipe down every piece of equipment they touch. Condition Monitoring has emerged as a leading Industry 4.0 use case for manufacturers and asset managers. Remotely tracking the health status of the industrial asset optimizes maintenance schedules, gains real-time alerts to operational risks, allows manufacturers to lower service costs, maximizes uptime, improves production throughput, and avoids proximity to the equipment. 

4. Wireless examination of complex-to-operate machines in a glass plant, 24/7 inspection of the cooling towers and fans responsible for the hygiene in chemical plants, inspecting the machines directly impacting the quality of the product in a Steel plant, scheduling predictive maintenance in a cement plant, avoiding loss of productive time in over-maintaining equipment in an automotive manufacturing unit, and digitizing conventional equipment to implement Predictive Maintenance are the thumb rules to address the setback during and after the pandemic. 

5. Infinite Uptime’s Industrial Data Enabler (IDE), a Make In India, patented edge-computing Vibration monitoring system for Predictive Maintenance remotely gathers triaxial vibrations, noise, and temperature of any mechanical rotating equipment in real-time. It empowers the Maintenance team to combat impending equipment damage in advance. Moreover, the end-to-end solution with visual indicators ensures maximum machine-availability, decreased inventory of spares and maintenance costs, and complies with the guidelines directed by the Government.  Not only does it help reduce maintenance fixed costs at a time where a reduction in costs and manpower is a dire need, but it also enhances social distancing by allowing remote monitoring of a plant without physical intervention.

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