Manufacturers lose revenue to unseen production problems

James Magee, CEO at OFS, said: “Manufacturers can spend millions on smart machinery and still have a visibility problem. Automated data is incredibly valuable, but a machine can tell you that a line stopped without necessarily telling you why it keeps stopping.

“The person running that line often knows. They understand the recurring issues, the context around a fault and the small changes that could prevent it happening again. When systems don't give them a simple way to capture that knowledge, it disappears into spreadsheets, paper notes, conversations and other workarounds.

“That matters commercially. Our research shows delayed visibility and unresolved problems are already contributing to downtime for almost half of manufacturers, increased costs for four in ten and lost revenue for a third.”

OFS argues that manufacturers need to rethink the traditional top-down approach to operational technology. Systems are often designed around leadership reporting and oversight, rather than around the people using them on the factory floor.

Instead, OFS advocates servant leadership. A shopfloor-first approach that combines automated line tracking with a simple way for operators to record downtime reasons, feedback and continuous improvement ideas.

Jonathan Newton, general manager Europe added: “Operators using workarounds shouldn't automatically be seen as resistant to technology. Often they are trying to capture something the official system doesn't allow them to say.

“The opportunity is to bring that knowledge into the same place as the automated production data. When operators can easily add the ‘why’ to the machine's ‘what’, manufacturers get a much richer picture of performance and can start tackling the root causes behind recurring problems.

“The frontline sees these issues every shift. Giving those people the tools to turn what they know into action is one of the most powerful ways manufacturers can continuously improve and prevent today's production problem becoming tomorrow's lost customer.”

To see the full report visit:

www.ofsystems.com/blog/blog-uk-manufacturing-research-report-2026