INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT

Issue 1, Volume 3, 2009

Production Monitoring System

for Monitoring the
Industrial Shop Floor Performance
S. K. Subramaniam, S. H. Husin, R. S. S. Singh and A. H. Hamidon

human element) and refers to principle of stopping work

immediately, when a problem occurs [1]. In the olden days
andon is a paper lantern which is a handy vertical collapsible
paper lampshade with an open top and a candle placed at the
central section of the closed bottom. To the ancient Japanese,
andon functioned as a flashlight, a signaling device in
distance, or even a commercial sign. The interaction of an
andon system is as shown in Fig. 1 below.

Abstract Efficiency and accuracy at the production lines enables a

better production and utilization of the available resources. The data
available should be interpreted accurately in order to identify the
various faults at production level and to immediately rectify them to
improve efficiency. An accurate data management and shop floor
monitoring system (PMS) is equally important in improving
production performance. A number of production floors are utilizing
manual methods of data collection for producing reports. Manual
data compilation leaves room for both inconsistencies and
inaccuracies. When manual data collection is practiced, there is
usually a second step of manually compiling the data. This is most
commonly accomplished by entering in the information into
spreadsheets. When the data is collected without the help of a PMS
then the data can be inaccurate. Where there is human intervention
on the recording or collection of data, the truthfulness of the
collected data is no longer reliable. This paper presents the benefits
and usefulness of an automated data collection and display system for
production lines. Once the data is displayed, it is transferred into
computerize spreadsheet in the remote office by authorized personnel
for reporting purposes. The system will generate an automated report
which stays in place and the management only needs to act base on
the results. This cost effective automatic data collection is the
alternative to manual data collection. It significantly improves the
accuracy of the valuable reports for the managements.

Responsible
personnel
Andon board

Switch
(operator)

Fig. 1 The interaction of andon system

It is a technical installation supporting execution of fourstep process of abnormality handling [1].

Keywords Production lines, Shop floor monitoring system, data

collection, production monitoring system, automated data display
system

I. THE CONCEPT OF JIDOKA

he andon system is one of the elements that make up

the principle of Jidoka. In ancient Japan. Jidoka is a
Japanese term for autonomation (automation with a

Detect the abnormality.

Stop.
Fix or correct the immediate condition.
Investigate the root cause and install a countermeasure.

The development of science and technology has seen many

new technologies being implemented. This result in the
evolution of the Production Monitoring System (PMS)
Nowadays, the systems of andon in many industries are
advanced into electronic devices with audio and color-coded
visual display.
There are many industries rely production data from such
devices to know their true production capacity. Some even
have computer bases system which is very high in accuracy
and better in performance in processing the production
information for each production shift. The most important
element here is whether the management is capable to improve

Manuscript received May 20, 2009: Revised version received May 20,
2009. This work was supported in part by the Universiti Teknikal Malysia
Melaka under Grant PJP/2006/FKEKK (12) S238 and PJP/2008/FKEKK
(17) S480.
Engr. Siva Kumar s/o Subramaniam, Siti Huzaimah binti Husin and
Professor Abdul Hamid bin Hamidon is attached with the Industrial
Electronics Department. Ranjit Singh s/o Sarban Singh is attached with the
Computer Engineering Department in the Faculty of Electronics and
Computer Engineering (FKEKK) in Universiti Teknikal Malaysia Melaka
(UTeM)
phone:
+606-5552021,
fax:
+606-5552112;
e-mail: huzaimah@utem.edu.my,
(e-mail: siva@utem.edu.my,
e-mail: ranjit.singh@utem.edu.my, e-mail: hamid@utem.edu.my ).

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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT

Issue 1, Volume 3, 2009

Developing a reliable system which is truthful in data

capture and displaying them is not a factor, yet there are
certain limitations in the available devices [2]. Based on
studies conducted, various approaches are taken to further
lessen the problems faced by the management in industries.
These problems are critical when there are human
interventions in the production process [2] - [4].
This study is conducted to develop a real time PMS to
replace human supervision on production lines. Information
from production lines is essential for the management to
enhance the production yield in all stages [2] [6]. Capturing
and interpreting this production data without human
intervention is a major challenge for the management.
Collected data may not be truthful due to the improper
monitoring system, the inaccuracy of the monitoring device
and human intervention.

their production process with the collected data Fig. 2 below

illustrates the production life cycle using the concept of
Jidoka.

A situation deviates
from the normal
workflow

The line is
stopped

Daily

A machine detects
a problem and
communicates it

improvements
Manager/supervisor
removes cause of the
problem

Improvements
incorporated into the
standard workflow

III. CONCEPT OF A PRODUCTION MONITORING

SYSTEM

Production life cycle on the

concept of Jidoka

The real time production monitoring system should provide

the right information to the respective personnel at the right
time. Presenting too much production information to the
production workers or operators is not essential to their task.
With too much unfocused information thrown at them, workers
or operators are not able to digest what is necessary to modify
on their current production outcomes. Whereby presenting too
little information to the supervisors, supporting departments
and the managers can be like watching the production
operations through a keyhole. Each level of people in the
industrial shop floor has their role in keeping up to the set
goals [7].
The most important requirements of any data collection and
reporting system is that the system is economical, accurate and
easy to set up on a production line. Supervisors generally have
an aversion to computer based systems because of ongoing
headaches with custom made software and other solutions.
They are often more comfortable with a production monitoring
system (PMS) which is capable of providing straightforward
connectivity to switches, sensors, PLC outputs and other
common industrial equipments. If a PMS can be easily
connected to each work stations and machineries on a
production line, then management needs for this critical data
can be easily satisfied. If the true production data can be
automatically captured and presented in a simple,
understandable way to the operators, they will become a more
integral part of the improvement process. An effective system
should be comprised of the following three elements:

Fig. 2 Concept of Jidoka in industries

II. INTRODUCTION TO PRODUCTION MONITORING

SYSTEM
A real time PMS is a production tool that helps the
management to gather and distribute information to everyone
in the shop floor as events are happening. Real time PMS is
essential in helping the industries to achieve realistic
production goals, at reduced down time and increase in yield.
The prototype of a PMS is shown in Fig. 3.

A. Collection
Connects to automated, semi automated and manual
production to count and collect data with minimal or no human
intervention.

Fig. 3 Laboratory testing using one of the PMS prototype

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Issue 1, Volume 3, 2009

B. Display
Presents relevant production information back to operators,
line leaders, supervisors, the supporting departments and the
management. Seven segment display panels have become the
method of choice of many industries because they can combine
the benefits of color with the numerical values.

This system should also proactively detect and react to the

faults by informing the relevant personnel in the departments
before they escalate. Data collected should be used in analysis
and should be ranked for further action. Base on the analysis
carried out, counter measures are applied for better results in
the on coming days.

C. Analysis
Should provide sufficient production data for the
management to conduct relevant analysis at all level in the
shop floor.

V. DESIGN ELEMENTS OF A REAL TIME

PRODUCTION MONITORING SYSTEM
The PMS is a complete system consisting of a display unit
for displaying the production status and alerts the respective
departments involved in the production process in the event of
a fault. There are two display boards in this PMS which are the
production time display and the non-production time display.
Real time PLCs are used as the primary control unit for this
system. The secondary control unit is used for generating
pulses for the display boards.

IV. TASK OF A REAL TIME PRODUCTION

MONITORING SYSTEM
The real time PMS in manufacturing industries enables both
the management and the production team to continually
monitor real time production status with regard to reliability,
accessibility and maintainability of the equipments.
Information must be collected at each shift end and
disseminated accurately in order to meet the production goals
[8].
The ability of the PMS to collect production information on
real time basis would enable the production team to respond,
in a timely manner, to solve any production related issues that
may arise.
The task of a PMS is to assist the production team to
produce their best within the available resources. Apart from
that PMS helps in improving quality matters and reducing
overheads. The layout of a PMS is shown in Fig. 4.

A. Production time display board

This display board displays information on the production
status when the production is running smoothly. This display
board will be used as a guiding tool by the production teams,
especially for the operators to know of their daily goals and
current achievements. The tower light attached to the
production time display board will be used to alert the
respective departments on the event of a fault. The five display
line on the production time display board helps both the
production team and the management to display details on the
production status.
Actual
This is the total number of completed parts or item from the
start of production. A signal will be generated to the PLC
using a few sensors attached on the work station to detect the
completed process. A signal then is generated to accumulate
the number of total completed parts on the display.
Target
This is the total number of parts or items set for production by
the management. In other words, target is the goal set by the
management for the shift. PMS has an accumulation target
shown to the workers and this will assist them in achieving the
set goals. The running goal is based on the cycle time of the
produced parts. At each complete cycle time, set in the PLC, a
signal is generated to add a number to the target display. In the
event a down time is recorded, this target will be paused for
the length of time taken to solve the faults.
Reject
This is the total number of parts or items produced that are out
of specification. This number takes into account the reject
(rework and scrap). A few sensors will be attached to the work
table to detect the event of faults and then a signal will be
generated by the PLC to add a number to the reject display.

Fig. 4 Layout of the real time PMS

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INTERNATIONAL JOURNAL OF SYSTEMS APPLICATIONS, ENGINEERING & DEVELOPMENT

Issue 1, Volume 3, 2009

management whereby the tabulated data and the changes are

monitored.
A post mortem report will be generated by the responsible
personnel to the management stating the specific factors
affecting the production lines and the counter measures taken
to reduce or minimize the highlighted problems.

Cycle time
This is the time-span for the specific parts or items to be
produced. This is usually set by the production planning and
control department (PPC) after a time study on the process is
done. The process cycle time will be programmed into the
PLC.
Planned stop
This is the length of time during which there is production.
This is when the workers have no productivity as planned by
the management. A switch will be used to generate pulses for
the display to capture the duration of no productivity.

SHOP FLOOR
Level 4
Operators / machineries

B. Non production time display board

This board will be used to capture the production
interruption time according to the departments involved in the
production process. Basically there are 3 main departments in
all industry which are the total quality management department
(TQM), PPC and maintenance department

Production Monitoring System

Production display board
(Target, actual, reject,
planned stop, cycle time)

Non production display board

Total Quality Management

This is when a fault is detected due to improper parts being
produced. The operators on the work station have to press the
switch to alert the department and at the same time the display
will capture the time taken to solve the fault.

Production Planning & Control

Total Quality Management
Maintenance
Others

Production Planning and Control

When the operator detects that they are running out of the raw
materials, then the operator have to press the switch to alert the
relevant department. At the same time the display will capture
the time taken to solve the fault.

Maintenance
When a fault is detected due to machine or technical failure,
the operator has to press the switch to alert the department and
at the same time the display will capture the time taken to
solve the fault.

Others
This display is used to capture the length of time taken by
outside vendors on their duration of work on production lines.
This could be an improvement process or system upgrading.

Level 3
Supervisor / line leader

Level 2
Maintenance
Total Quality
Management

Level 2
Production Planning
& Control

Data
collection and
basic analysis
is carried out

VI. PROCESS FLOW OF THE REAL TIME

PRODUCTION MONITORING SYSTEM
The implementation of a PMS and its operation flow is as
shown in Fig. 5. Data displayed is collected by the supervisor
or the line leader as in level three in the shop floor of
industries for analysis.
The data will be tabulated into a spread sheet by the
production team in level two. Table 1 shows the types of data
collected and the possible analysis which can be carried with
the available data. Based on the daily performance of the shop
floor, basic analysis is attempted to ensure better production
performance to the set bench mark which is set by the PPC and
the management. The final level of analysis is done by the top

Detail analysis is
carried out and
counter measures
are taken

Level 1
Management

OFFICE
Fig. 5 Production information and data flow in a typical
industrial shop floor
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Issue 1, Volume 3, 2009

VII. USEFULNESS OF A REAL TIME PRODUCTION

MONITORING SYSTEM

A second step of studying the problems and counter

measures is designed by the management in level 1to be in line
with the companies target. The counter measures are directed
to the proper channel to detect and rectify them.

The benefits of installing an effective and efficient real time

PMS is the immediate on screen access to all production
related
information.
Besides
relevant
production
informations, the system also helps various level of people in
industries to optimize their performance at all means.

Table 1: Factors on mail delivery

Responsible
personnel

Data collected

Analysis

Operators

Target, actual
output, rejected
output, planned
stop duration.

Comply to set
targets and
rejects cost

Operators

Down time of
all supporting
department.

Non

Supervisor/
line leader

Targeted
output, actual
output, rejected
output, planned
stop duration
and down time
of all
supporting
department.

Down time
factors, unmet
targets, rejection
rate, man power
utilization,
planning for next
production.

Down time of
all supporting
department.

Down time
factors, unmet
targets, rejection
rate, preventive
maintenance,
production line
improvement and
OEE.

Flow

Production
team
Production
team

Production
team

Management

Management

Supporting
department

OEE, man
power
utilization,
performance of
the supporting
department and
production
status

Detail analysis
on all factors of
production and
improvement is
being planned.
Distribute
improvement
plans by
responsible
departments.

OEE, man
power
utilization,
performance of
the supporting
department and
production
status

Corrective
measure being
implemented on
both operators
and machineries.

A. Man Power (Operator)

The proposed PMS is a reliable tool for assisting the
operators especially in informing operator of their
performance to date.

Production planning & control

Total quality management
Others
Maintenance

React to the problem

Production
Monitoring System
Operators /
machineries

Problem fixed
(Back to production)

Faults detected
(Production interruption)

Fig. 6 The process cycle to problem solve faults at work

stations using PMS
The PMS also will be able to guide the operator to maintain
a consistent pace throughout the day and this will result in a
better implementation of work morale among the employees.
Once the operators have been tuned to react according to the
PMS, this will automatically eliminate wasted time and hence
produce more units per hour.
This system also empowers the operator to recognize faults
and react to the system by alerting the respective departments
to solve problems as they occur as shown in Fig. 6. Such
interaction reduces the duration spend to alert the respective
personnel and thus increases the efficiency of interaction
between the production lines (operators) and all the
supporting departments.
B. Machineries
Detail analysis will help the management and the production
team to visualize truthful data on their machineries. With such
valuable data, further improvement on the productions
performance especially involving machineries and unwanted
wastages can be eliminated. The available data on each
machine can be categorized in 3 different aspects and
summarized into a single number which reflects the machinery.

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Issue 1, Volume 3, 2009

VIII. CONCLUSION

The first category is the availability which reflects the

availability of the machine (running time) [9] [10]. This will
indicate the total usage of the machine for each shift. The
machine utilization can be counted in numbers rather than
assumption. The second category is the performance which
reflects the performance of the machine (speed) [9] [10].
This will indicate the actual running status of the machine for
each shift. The third category is the quality which reflects the
quality of products produced by the machine [9] [10]. This
will show the management the ratio of good parts being
produced over the total produced parts for each shift. All the
three above elements provides a complete measure of
manufacturing efficiency in a single number which is the
overall equipment effectiveness.

The PMS developed is an essential production tool in

industries for both the management and the production team.
The PMS captures and distributes unadulterated production
information at all levels along the production process without
human intervention. Data collected is crucial and this could be
collected by using a real time production monitoring system.
With the collected data, realistic production goals can be
achieved when proper analysis is done and implementation is
practiced. Events occurring can also be displayed with the
help of a PMS. Production faults can be rectified instantly. A
PMS enables the production team to operate efficiently
optimizing all available resources towards a better production.
The real time production monitoring system works
alongside OEE [11] [13]. The awareness of OEE is vital
when it comes to decision making. Companies have begun to
value the great strength of OEE in its ability to help the
management improve the overall operation performance of
their machineries. With OEE decision making is made easy.
The simple metrics of OEE brings to light all the valuable
information required by the management [14] [17].
One of the greatest strength of industries is human capital,
whereby they are considered as the major role player in the
development of our industries [18]. With the real time
production monitoring system on one hand, it helps the
management to efficiently monitor the workers and drive
towards optimum man power utilization which is in line with
the set requirements of industries. Information on human
capital will further strengthen the true capacity of the workers
performance not only on the production lines but also to the
supporting departments involved in the production process.
When man power utilization is being optimized, this will
engage morale towards a better production yield [18].
With the limited resources available on the industrial shop
floor, the practice of using real time production monitoring
system is crucial. The PMS should be fully utilized so that
whatever resources available within the industrial sector were
not wasted but used to the optimum to improve the production
yield [18] [19]. By taking these necessary steps industries
can improve and maintain a more efficient production line.

C. Supervisors
PMS also benefits the supervisors and the line-leader
whereby it act as a supervisory tool, which enables the
movement of people (operators) from one job to another when
operators are absent or unable to meet production
requirements. Such a display system helps the supervisor to
monitor the performance of their production lines by referring
to the parameters displayed. This will help them to keep the
production output back on track to meet set goals within the
planned production duration. The process flow of the PMS is
shown in Fig. 5 illustrates the task of the supervisor (level 3).
D. Production team
The proposed PMS helps the production team to ensure
production goals to be established and monitored continually.
Apart from that PMS also helps to increase production at
controlled production costs, at all levels of work force, within
the set targets and enable continuous improvement of line
balancing (bottle neck). PMS helps to screen the work
progress and creates awareness when work is not flowing, i.e.
it sustains the required production output. The process flow of
the PMS as shown in Fig. 5 which illustrates the chore of the
production team (level 2).
E. Management
All production related information is presented to the
management and supervisors via display boards. These
eliminate the clerical error which makes reporting easier
compared to conventional methods. Relevant production
information can be generated base on the industry requirement
and this will help the management to summarize throughput,
work in progress, stock information (produced parts) and
work around solutions as problems occur. From the data-base
the management can also eliminate bottlenecks, unwanted
wastage and production interruption.
As a result of the analysis the managements can make
counter-measures to ensure better efficiency and capitalize on
the available resources for generating better production yield.
The process flow of the PMS as shown in Fig. 5 illustrates the
task of the management (level 1).

ACKNOWLEDGMENT
The authors would like to thank the following manufactures
for their generous efforts and help in many means. They
furnished photographs, drawings and various technical
information for this research. Without their valuable time and
effort this article would have been possible. The authors hope
this acknowledgment of some contributors will let readers
know that the field they are working in or are about to venture
is one of the most demanding filed around the globe.
Individuals, too numerous to mention, have also played a role
in contributing towards this article. The authors would like to
take this opportunity to also thank them for their contributions.
Oriental Summit Industries Sdn. Bhd.
Provience Industrial System Sdn. Bhd.
A.I. Automation Sdn. Bhd.
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Issue 1, Volume 3, 2009

[13] Simon Bragg, "Implementing OEE".

ARC Insights, Insight#2003-07E,
ARC Advisory Group,
Issue February 12.
[14] Siva Kumar a/l Subramaniam, Siti Huzaimah binti Husin, Yusmarnita
binti Yusop and Abdul Hamid bin Hamidon, The production
performance monitoring system.
The 6th WSEAS International Conference on Circuits,
Systems, Electronics, Control & Signal Processing
(CSECS07) World Scientific and Engineering
Academy and Society, 29-31 December 2007,
Page(s):185-190.
[15] Productivity Dev Team, OEE for operators: Overall
Equipment Effectiveness
Productivity Press. July 1999,
Page(s): 4-7.
[16] Robert C.Hansen, Overall Equipment
Effectiveness. First edition
Industrial Press, December 2001,
Page(s): 1-20.
[17] Killeen, D., Gaboury, P. & Paccard, D., Managing,
measuring and improving equipment capacity and
overall equipment efficiency (OEE) using iPLUS.
2001 IEEE International Semiconductor
Manufacturing Symposium, 8-10 Oct 2001,
Page(s): 25 28.
[18] Siva Kumar a/l Subramaniam, Siti Huzaimah binti Husin, Yusmarnita
binti Yusop and Abdul Hamid bin Hamidon, 2009, Machine efficiency
and man power utilization on production lines,
Proceedings of the 8TH WSEAS International Conference on
Circuits, Systems, Electronics, Control & Signal Processing,
Page(s): 52-56.
[19] Vorne Industries Inc., July. 9, 2007
URL:
http://www.vorne.com/pdf/fast-guide-to- oee.pdf

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BIOGRAPHIES
Siva Kumar Subramaniam was born
on 16 July 1981. He received his
Diploma of Electronics Engineering
from Politeknik Ungku Omar,
Malaysia in 2002. He then
graduated with a Bachelor Degree
in
Electronics
Engineering
(Industrial
Electronics)
from
KUTKM Malaysia in 2006 and his
Master studies in Electronics
Engineering in the same institution
in 2009 which is now known as
Universiti
Teknikal
Malaysia,
Melaka. Since his keen interest in
industries matters and strong
support from the university, the
author is involved in the development of the industrial based application such
as monitoring systems, automation for industries and control base
applications. Engr. Siva Kumar has a few collaboration with industries in
accomplishing a number of research projects and consultancy works in
Malaysia for the past few years. Apart from research works with industries,
Engr. Siva Kumar also supervises secondary school students for their final
year projects. He was involved in such projects from his basic degree whereby
he won bronze medal in national and international competitions such as the
MTE (07 & 09) and ITEX (07 & 09).

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Issue 1, Volume 3, 2009

Siti Huzaimah Husin currently

working as a lecturer and also the
Head of department for the
Industrial Electronics Department
in the Faculty of Electronics and
Computer Engineering, Universiti
Teknikal Malaysia Melaka. She
gained her first Degree in
Electronics
Engineering
(Telecommunications)
from
Multimedia Universiti Malaysia in
2001. In 2005, she graduated with
Master in Electrical Engineering
from Universiti Tun Hussein Onn,
Malaysia. Her filed of interest in
research is focused on embedded
system especially on the finished products to solve industrial problems. Siti
Huzaimah is a researcher who actively works with various industries and
private organizations in many research works for the past 4 years. Siti
Huzaimah has also been actively competing and exhibition in numerous
competitions and exhibitions in both local and International events whereby
she have won bronze medal in MTE 2007 and ITEX 2007.

Ranjit Singh Sarban Singh was

born on 30 April 1982. He received
his Diploma of Technology
Computer
(Electronics
Engineering)
from
Politeknik
Seberang Perai, Malaysia in 2003.
He then graduated with a Bachelor
Degree in Electronics Engineering
(Computer Engineering) from
KUTKM Malaysia in 2006 and
currently he is pursuing his master
studies in Master of Science
Engineering
in
Multimedia
University, Melaka Malaysia. His
keen interest is in image processing
motion estimation and electronics
applications. Besides that, the author is involved in the development of
motion estimation algorithm application, actively involved in smart consumer
electronics applications. He was involved and won medals in national and
international competitions such as the MTE 09 and ITEX 09.

Abdul Hamid bin Hamidon @

Hamid Don was born on 3 March
1950. He received his Bachelor of
Electrical
Engineering
from
Monash University, Australia and
Masters of Science (Electronics)
from the University of Wales
Institute
of
Science
and
Technology, Cardiff, Wales. In
1976 he began his career as lecturer
with Fakulti Kejuruteraan Elektrik
UTM. In 1986 he was promoted to
Associate Professor and made the
Deputy Dean (Academic) for 6
years. In 1995 he was Director of
the Student Support Services Unit.
He was also Head of the RF Subsystem Research Group and was responsible
for several course and curriculum development. He was one of the task force
responsible for the development of KUTKM now known as Universiti
Teknikal Malaysia, Melaka. In 2001 he promoted to Professor and was made
the Dean of the Electronic and Computer Engineering Faculty.

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