Batch production has the characteristic that components are completed at each stage before moving to the next. Batch production is popular in bakeries and in the manufacture of pharmaceutical ingredients, inks, paints and adhesives etc

Batches are planned to minimize cleaning and setups between individual batch runs. For example when manufacturing paints, runs will be set up from light to dark colours reducing cleanups between batch runs.

Companies that have many product variations will run them down a single line to reduce capital outlay. The optimization of the line setups/ changeovers and downtimes due to product variations is critical to achieving a profitable business.

 
Gemba’s Modular GAIN4 solution addresses batch production problems with the following features :

• User Configurable real-time batch production scoreboards (GAIN4 Andon)
• Real time monitoring of downtimes and the reasons for them (GAIN4 Efficiency)
• Monitoring and warnings of batch changeovers (GAIN4 Efficiency and Alerts)
• Recording of critical batch process parameters for compliance (GAIN4 Advanced reports)
• Planning of batch runs to minimize change over’s (GAIN4 Planning)
• Monitoring Labour usage in the facility (GAIN4 Labour)

Benefits:

• Reduction in raw material usage by optimizing yield levels
• Identifies and releases hidden production capacity
• Provides information for downtime campaigns
• Provides full product traceability for compliance records