In a recent episode of Zen and the Art of Manufacturing between Bryan Sapot, VP of Smart Factory at Nulogy, and Jesse DePriest of 5L Performance, one message came through loud and clear: when it comes to tracking manufacturing performance, start simple.
For many production managers, the pressure to improve metrics like OEE, cycle time, capacity, and downtime can lead to over complication. There’s a temptation to track everything from the start—every sensor, every event, every machine. But more data doesn’t always equal better decisions.
Begin with the Problem You’re Trying to Solve
As Jesse put it, “It’s always a bit of a hypothesis. What are we trying to do? What are the biggest problem areas?”
Rather than collecting massive amounts of data and trying to make sense of it later, effective continuous improvement begins by asking:
- Where are we losing the most time or productivity?
- What’s keeping us from hitting delivery targets?
- Which lines or shifts are most inconsistent?
Once you’ve identified the critical problems, you can zero in on the few key data points that provide the most insight into those issues. This could be as simple as measuring:
- Total downtime by reason code
- Cycle time variance on your most important line
- First-pass yield on a product with frequent rework
The Power of Leading vs Lagging Indicators in Manufacturing
Jesse highlighted a common trap in manufacturing: focusing only on lagging metrics—outcomes like OEE or scrap rate that you can’t change once they’ve happened. Instead, focus on leading indicators that inform what’s happening in the process now.
It’s the difference between quality control (measuring outcomes) and quality assurance (monitoring the process). If you believe in your standard work and measure performance during production, the outcome should take care of itself.
Smart factory software like Nulogy makes this possible by collecting real-time data directly from the factory floor and displaying it on live dashboards. Operators and supervisors can see immediately when a line slows down, when changeovers take too long, or when cycle times drift out of spec—long before OEE drops.
Why Start Simple? Because It’s Manageable
The goal isn’t to drown in dashboards—it’s to empower your team with actionable data. Starting with one or two metrics that matter creates a foundation for long-term success. Once those are in place and reliable, you can add more layers of insight—build trend lines, compare shift performance, monitor tooling or maintenance issues.
This approach also avoids the common failure point of continuous improvement programs: unrealistic expectations and too much complexity too soon. As Bryan Sapot shared in the discussion, manufacturers that succeed start with simple visibility into key areas, see quick wins, and build momentum.
Use Smart Factory Tools to Build the Right Habits
Nulogy Smart Factory is built with this “start simple” philosophy in mind. It’s fast to deploy and easy to scale—whether you’re starting with downtime tracking or building a full OEE improvement initiative. The platform helps you track exactly what matters most, from one data point or line to your entire operation.
Many Mingo customers see ROI within three months simply by replacing manual reporting with real-time visibility. But the long-term value comes from using that visibility to create a habit of continuous improvement—measuring the process, not just the result.
Start Simple, Think Big, Move Fast
If you’re not sure where to begin, don’t overthink it. Pick one line, one metric, one process. Understand it. Measure it. Improve it. Then do it again.
That’s the work of management—and that’s how you build a culture of performance on the shop floor.
Ready to see how smart factory software can help you start simple and scale improvement? Check out the article on starting simple or request a demo today.
