The 1%: What can you do with it?

What’s hiding behind your 1%?

In the world of Industry 3.0, manufacturers have been on a journey toward 99% quality in their factories. Some are close, some are already there prompting the question, what can you do with just the 1% left? At first, it seems like there is no more continuous improvement to be had. However, the tools and processes of Industry 3.0 also baked in the assumption that, to achieve 99% quality, it was acceptable to have 60, 50, 40 even as low as 30% efficiency and asset utilization. With the power of data and Industry 4.0 tools, this tradeoff is no longer necessary.

In this paper, we examine the path that got manufacturers to their current Pareto optimal solution, the limitations of these old tools, and how new tools are creating tremendous efficiency opportunities at similar or even higher quality. Ultimately, we seek to answer the question – what’s hiding behind your 1%?