In manufacturing, it’s tempting to assume that more machines mean more parts and higher throughput. When demand increases or bottlenecks appear, the instinct is to consider buying another machine to boost capacity. But how can you be sure a new machine will actually improve overall throughput?
Start with Data, Not Dollars
Before signing off on a six-figure capital expense, it’s critical to understand how efficiently your existing machines are performing. Minitab’s newest offering, DataXchange, collects real-time utilization and performance data from your current equipment, revealing how much capacity you already have available.
Instead of asking, “Can we afford another machine?” you should be asking “Are we fully using the machines we already have?”
Measure True Utilization
DataXchange continuously tracks machine run time, idle time, and downtime reasons across your entire shop. By visualizing this in easy-to-read dashboards, you can quickly see:
- Which machines are running below capacity
- How much downtime is planned vs. unplanned
- When your machines are truly bottlenecked
If a machine’s utilization is only 60–70%, adding another one won’t solve the problem—it will simply multiply inefficiencies.
Identify Bottlenecks with OEE Insights
Overall Equipment Effectiveness (OEE) gives you a clear picture of whether production losses come from availability, performance, or quality. DataXchange calculates OEE automatically, highlighting the true root cause of throughput issues.
For example:
- If availability is low due to setups or scheduling gaps, a new machine won’t help—you need better planning.
- If performance is low due to tool wear or feed rates, the fix might be maintenance or operator training.
- If quality is the issue, investing in process improvements yields far greater ROI than buying new hardware.
Analyze the Root Cause
Armed with data from DataXchange, utilize Minitab Statistical Software to identify patterns and locate areas of improvement. Use Minitab Brainstorm to figure out issues and root causes of the problem(s).
Quantify the “What-If” Scenarios
Once you’ve identified an improvement opportunity, use Minitab Simul8 to you run “what-if” scenarios before implementation. This way you can see if reducing downtime or improving changeover efficiency will reap true rewards.
If you can’t identify a problem with a machine, use “what-if” analysis to model different operational scenarios like whether or not you achieve throughput gains from adding another shift vs. adding another machine.
Track and Sustain the Improvements
Utilize DataXchange to continuously monitor current utilization of machines and OEE data, Harness the power of Minitab Connect to get live control charts of OEE to monitor changes and identify potential changes before they occur.
Don’t Just Add Machines—Add Insight
Manufacturers today face tighter margins, longer lead times, and tougher competition. The winning strategy isn’t always “buy more.” It’s “use what you have, better.”
With Minitab solutions, gain the visibility to make that call confidently, helping you uncover hidden capacity, reduce downtime, and make investments that truly move the needle.
Visit Minitab to see how your OEE data can power your next breakthrough with Scytec.
