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The Greer Monitoring System "The Production Tracking and Reporting System that Produces Immediate and Sustained Results."

How would you like to walk through your plant knowing that you and each and every employee know their exact efficiency at any given moment? What if this was through large individual touch screen displays with bar graphs that could be seen from a distance? Wouldn't it be great if they displayed the employee's first name, last name, item name and rate? What would it be like for you and the employee's to have the comfort of knowing the data being collected is 100% accurate? What if you could print a report of your choosing simply by a click of the mouse? What if you had a monitor in your office and it displayed the realtime overall efficiency of the entire plant? What if the monitor could also display the realtime efficiency of each and every machine and employee? Wouldn't it be great if it showed the items that the employees were running too? How about displaying each employee's logged on time for the day as well as their item and overall efficiency?

Well, look no further. The Greer Monitoring System (GMS)does all of that and more. Time tested and upgraded in American Textile Maintenance's facilities over the last 3 years, GMS has been shown to help increase and sustain efficiency with less effort. If implemented correctly, the result could be the whole system paying for itself in less than 2 years.

Studies have shown that there are two main reasons for production increases. When people spend a large portion of their time at work, they must have a sense of belonging, of being part of a team. When they do, they produce better. The other is if workers are being subtly observed. When they know they are being observed or monitored, they produce better. As you read on, you will see why GMS is a great tool to implement these two principles.

GMS Main Screen


 

BG Industrial Control has developed the "Greer Monitor System" (GMS), a unique software product to control, monitor and report on the efficiency of your plant and the work status of your employees.

With the advent of the GMS, there is no longer a need to manually collect and process status and performance data from your plant machines and employees.

GMS collects and aggregates thousands of key performance indicators across all plant machines and employee activity in realtime. Its powerful reporting system can then deliver clear and concise reports on a variety of time frames by work station or employees and sorted by any parameter at a push of a button.

Imagine the increase in efficiency by eliminating the manual task of collecting performance data by supervisors and managers. Imagine the time saved by supervisors and managers by having accurate and timely information when employees start and end their shift.

“After installing GMS in our plant our efficiency has  increased 10 to 15% and we are able to sustain it. There is no more  gathering of data to enter into an excel program GMS does all this  for us. We can run numerous reports at a touch of a button.  The Layout Screen is incredibly helpful with real time data.”  Bob Brill, Republic Los Angeles ”We once had a grievance and we could not disprove  it because our data was collected by other employees. This will  never happen to us again. The data by GMS is collected automatically  with no employee intervention and is 100% accurate. The system frees  up our supervisors to do a better job.”  Brad Shames, American Textile Maintenance At Republic Long Beach the system was installed and the first week they had to send the flat department home one day early. They have since doubled their business and added a second shift. When adding the second shift they knew the exact production of the second shift by running the Daily Item Report the next morning. Employee  probation periods have been a snap. Just run a Weekly Item Report for the time  frame and out comes the efficiency of all the employees. No need to guess or  have bias. Kenny Imaizumi of Republic Medico was not sure if his production had increased  after installing GMS but after seeing the overall plant efficiency bar graph  on the layout screen consistently reading over 100% he now agrees his  efficiency has increased considerably.

The Greer Monitoring System

There are three main ingredients to the Greer Monitoring System: Layout Screen, Report Menu Screen and Employee Touch Screens.

Layout Screen


 

The layout screen encompasses many variables. The bar graph and digital display in each machine show the combined item efficiency for the machine. By clicking on the individual machines you can display variables in real time for the machine. The benefits of this screen are many. You can display the realtime efficiency of each machine, employee or the whole plant.

• Logged on or off
• Employee name and number
• Item name and number
• Item count
• Item efficiency
• Item minutes
• Total minutes
• Total efficiency

The red squares below each station indicate the current efficiency of the station.

• Purple indicates they are logged off
• Red indicates their efficiency is below 75%
• Yellow indicates their efficiency is between 75 and 99%
• Green indicates their efficiency is 100% or above.


The red bar graph indicates the overall plant efficiency. This is arrived at by aggregating the individual efficiency of every employee logged in.

 

Report Menu Screen



(Click on image to view larger version)

The supervisors generally begin their day by going to the main screen on the computer
and clicking on the report menu. They run the Daily Item Report for the previous day.
This gives them a detailed report of the previous day’s production by employee.

Daily Item Report

The Daily Item Report shows the Supervisor the following information:

1. Sorting is by employee first
2. For each employee it sorts by each item processed
3. For each item processed, it displays the following
1. Time and Date
2. Goal in pieces per hour
3. Total pieces
4. Total time
5. Actual pieces per hour produced
6. Total efficiency
4. It also displays the total times an employee logs in and out
1. In the normal course of the day, an employee should not log in and out more than 10 times. If they do, it is because there is a machine problem or they are logging out when waiting for items.
2. Displays in black ink if less than 10 or other desired number.
3. Displays in red if preset number is exceeded.

 

Employee Efficiency Report



With this report, they can head off any problems. If an employee’s production is low or they logged in and out too many times, they can run an Employee Efficiency Report for the previous day. This gives them a detailed report of that employee from an efficiency perspective.  The Employee Efficiency Report shows the supervisor the following information.

1. Sorting is by employee
2. Displays each Log On and Log off period
1. Displays machine and station number
2. Displays Item Name
3. Displays Item count
4. Displays Item minutes
5. Displays Item efficiency
6. Displays Goal in PPH
7. Displays Actual PPH
8. Displays Total minutes
9. Displays Total efficiency for the day

Here they can gather information before having to go around the plant asking questions. They also don’t have to interrupt the employee’s production for that day either by asking them, why they logged in and out so much? They can see if the machine had excessive down time or was there some other issue not related to the employee that caused the lower performance. From the Employee, Efficiency Report they can also see if the employees are at there work stations on time. In larger plants the supervisor can not monitor everyone to see if they were at their work station on time. With the Efficiency Report all they have to do is look at the first record after their assigned time to log on. There is a date time stamp on the report indicating whether the worker was on time to their work station.

You can also update system data effortlessly. Simply click on what you want to update and type in the information.

Sample Reports

Click on a menu item below to view a sample report in PDF format.
You must have Adobe's PDF software installed to view these reports.





Employee Touch Screen



The employee begins their day by clocking in at the terminal at their assigned work station. The terminal is the point where the employee logs in and out for the day and changes the items they are processing. The terminal shows them the following basic information throughout their shift.

1. Time and Date
2. Employee Number
3. Employee first and last name
4. Item name and number


It also tracks their productivity by:


1. Item rate
2. Speedometer - Calculated data for the last minute
3. Odometer - Calculated data for the item for the day

This ability to see their productivity during the day provides employees real-time feedback and allows the employee to see their performance and measure themselves against a visible goal as they work. There are many benefits to this screen.

Employee Benefits

By displaying the workers first and last name on the screen the workers have a sense of belonging. A sense of ownership. This is their station and the information accurate. It shows that management cared enough to display their name and not just a number. It also sets a daily goal for them each and everyday with real time feedback on how their production is going compared to the goal. The benefit to having the efficiency displayed in the form of a bar graph is the workers can see their production peripherally. When they reach their goal the workers self esteem improves. There is also the peer pressure of the team to perform when they work in groups such as a small piece ironer with 5 stations. The workers also know they are being subtly observed or monitored.

Supervisor Benefits

There are a number of benefits for the supervisor. As they walk through the plant they can instantly see how production is going and head any problems early before they magnify. They can also see if everyone is logged on and on the correct item. They also have the benefit of knowing every worker is monitored so they don’t have to watch everyone. This management style is less evasive and more effective.