Smart Manufacturing Maturity Assessment Tool
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Discover your factory's Smart Manufacturing maturity level.
This Smart Manufacturing maturity assessment provides clarity about your level of digitization of plant floor operations.
Click the button below to start the assessment, which will take about 5 minutes to complete.
Disruption Digital Tracking
How are you capturing and addressing production disruptions?
Answer by selecting one of the following:
Machine breakdowns tracked manually on whiteboards, logs, or spreadsheets
Machine breakdowns tracked manually and input after the fact into the CMMS / EAM
Disruptions such as quality, material, training, maintenance, etc are logged in real-time
Machine AND process disruptions captured in real-time, but in separate software applications
Disruptions such as quality, material, training, maintenance, etc are logged in real-time
Process AND machine disruptions captured on the same Smart Manufacturing Platform
Disruptions such as quality, material, training, maintenance, etc are logged in real-time
Process AND machine disruptions reported and tracked via integration and IoT devices
Low maturity
High maturity
IoT / Sensors
How are you using IoT sensors in your plant(s)?
Answer by selecting one of the following:
Internet of Things (IoT) devices are not broadly used on the shop floor
Capturing equipment data from IoT sensors to predict and avoid specific machine failure modes
Using IoT data as a basis for condition-based and predictive maintenance program
Using IoT data for broader set of applications such as product quality measurement devices, recipe and centerline monitoring
Data from IoT based devices are used to create machine and product Digital Twins
Low maturity
High maturity
Escalation & Notification
How do you handle notifications and escalations when disruptions occur?
Answer by selecting one of the following:
Audio and/or visual Andon indicators are used to signal issues
The factory uses various forms of communications (text, phone, radios) to communicate issues
Disruption notifications are auto-sent as text messages when issues occur
Notifications are auto-generated and received on IOS and Android platform app
Customized leadership escalation protocols are managed via a digital solution and smart devices
Low maturity
High maturity
Predictive & Preventive Maintenance
How are you handling predictive and preventive maintenance events?
Answer by selecting one of the following:
Preventative maintenance managed manually on external calendar or spreadsheets
Maintenance work planned and launched via a stand alone CMMS / EAM
Support events (Calibration, QA Audits, Changeovers, etc) launched via a digital solution
Preventative, Planned and Predictive events launched based on cycle and IoT data
Process AND machine disruptions reported and tracked via integration and IoT devices
Low maturity
High maturity
Spare Parts / MRO Process
How do you manage and track your spare parts / MRO process?
Answer by selecting one of the following:
Parts inventory and counts tracked via a spreadsheet or logs
Inventory and consumption data is tracked in a stand-alone CMMS or MRO solution
Inventory and consumption data is tracked in real-time via mobile devices
Inventory and cost data is attached to disruption events in real-time via mobile devices
Mobile/Cloud integration with ERP for consumption and reorder using barcodes and RFID devices
Low maturity
High maturity
Labor Data Tracking
How do you track your labor data?
Answer by selecting one of the following:
Labor data is tracked via a spreadsheet or using timeclock tracking data
Labor data is tracked in disparate systems such as CMMS, MES and ERP
Labor data for support events and production is tracked in the same Smart Manufacturing system
Labor data is tracked and time-stamped in real-time as employees are assigned. And employees can interact with events in a Smart Manufacturing Platform via mobile devices.
Time-stamps cannot be changed by the employee
Labor data is tracked as users interact and data is rolled automatically to metrics
Low maturity
High maturity
Production Data Tracking
How do you track your production data?
Answer by selecting one of the following:
Production actuals are manually collected and placed on whiteboards, logs, or spreadsheets
Production demand and actuals are captured manually or digitally in an MES
Production demand and actuals are captured via a cloud-based system and displayed digitally
Demand and actuals are captured and used to calculate plant metrics on dashboards
Production data is captured through integration with plant metrics calculated and displayed in real-time
Low maturity
High maturity
Data Visualization & Analysis
How do you visualize, display, and analyze your data?
Answer by selecting one of the following:
Data is collected manually and input into spreadsheets and pivot tables
Data is collected from separate systems and placed into a data lake for manual display and analysis
Data lake data is pulled through to Power BI or Tableau for calculation and display
Data captured in real-time and displayed without the need for separate BI systems
Data displayed In real-time with charts and graphs auto-generating based on user customization
Low maturity
High maturity
AI / Machine Learning
How are you using AI and Machine learning in your processes?
Answer by selecting one of the following:
Artificial intelligence (AI) or Machine Learning (ML) features are not used on the shop floor
Machine learning and AI are incorporated into defect detection and robotic failure learning
IoT and failure data are used for machine learning and predictive maintenance requirements
Captured data is used in an AI application to improve product and process design
AI is used to create process and product digital twins to improve throughput, quality and safety
Low maturity
High maturity
Document Control
How are you handling your overall document control?
Answer by selecting one of the following:
Documents are stored in a shared folder and printed for use
Documents stored in one or more stand-alone document control systems and printed for use.
Likely not easy to access for some roles on plant floor.
Documents accessible through a cloud-based system and accessed digitally (not printed)
May or may not be easy to access for various roles on the plant floor.
Cloud-based system with interactive features on a mobile device.
Features such as capture checklist, measurement and process data. Easy to access for all roles on plant floor.
Documents and work instructions are accessible via augmented reality devices
Low maturity
High maturity
Training & Skills Management
How are you managing your Training and SKILLS for shop floor employees?
Answer by selecting one of the following:
Training matrix is stored on spreadsheets in local shared folders
Training matrix and skills are tracked on an external LMS (Learning Management System)
Training and Skills are tracked directly to individual users and roles on a single platform
Required skills are tied directly to jobs and tasks as users perform them in real-time
Training and Skills accessible at the worksite from augmented reality devices
Low maturity
High maturity
Lean Manufacturing Practices
How are you managing your LEAN manufacturing practices?
Answer by selecting one of the following:
Lean documents are stored in local shared folders and printed for use on the factory floor
Standard lean practices are implemented across the enterprise, but still managed locally in a manual fashion
Enterprise standard lean practices and outcomes are shared via meetings and email
Lean practices and events are managed in a single cloud-based system with global access
Ideas, Kaizens and problem solving can be shared with all sites on a digital platform
Low maturity
High maturity
Systems Integration
How mature is your systems integration?
Answer by selecting one of the following:
None of your shop floor systems are integrated with each other
Integration of raw production data to SCADA systems with display boards on the shop floor
Machine and CMMS systems integration with shop-floor MES exist
Integration of MES and ERP systems to your Smart Manufacturing Platform
Total integration are all disparate systems to a Cloud-based Smart Manufacturing Platform allowing for instant data access
Low maturity
High maturity
Your Smart Manufacturing Grade
%
Download our Smart Manufacturing Roadmap eBook
Now that you have a smart manufacturing grade for each of the 13 manufacturing operations processes, use this guide to understand the next steps to take toward success in each area.
Disruption Digital Tracking
How are you capturing and addressing production disruptions?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 90%
IoT / Sensors
How are you using IoT sensors in your plant(s)?
%
Your Answer
Benchmark
Average Score: 40%
Top Companies Score: 70%
Escalation & Notification
How do you handle notifications and escalations when disruptions occur?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 90%
Predictive & Preventive Maintenance
How are you handling predictive and preventive maintenance events?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 70%
Spare Parts / MRO Process
How do you manage and track your spare parts / MRO process?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 70%
Labor Data Tracking
How do you track your labor data?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 70%
Production Data Tracking
How do you track your production data?
%
Your Answer
Benchmark
Average Score: 70%
Top Companies Score: 80%
Data Visualization & Analysis
How do you visualize, display, and analyze your data?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 70%
AI / Machine Learning
How are you using AI and Machine learning in your processes?
%
Your Answer
Benchmark
Average Score: 50%
Top Companies Score: 60%
Document Control
How are you handling your overall document control?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 70%
Training & Skills Management
How are you managing your Training and SKILLS for shop floor employees?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 70%
Lean Manufacturing Practices
How are you managing your LEAN manufacturing practices?
%
Your Answer
Benchmark
Average Score: 70%
Top Companies Score: 70%
Systems Integration
How mature is your systems integration?
%
Your Answer
Benchmark
Average Score: 60%
Top Companies Score: 80%