Integration

Integrating TrakSYS with iObeya to Improve KPI Visualization and Operational Efficiency in Lean Manufacturing

Challenges Before Digitizing Lean Factory Operating System: Manual KPI Management and Data Silos
Solution: Integration of TrakSYS with iObeya for Real-Time KPI Updates
The Operational Impact of Centralized and Real-Time KPI Reporting
High-Level Overview of the Integration Steps:
Digitizing Lean Operations with iObeya: A Scalable Solution for Manufacturing to Achieve Operational Efficiency
Take the Next Step Towards Operational Excellence with iObeya

In the modern manufacturing world, real-time data visualization is a critical component of ensuring smooth operations and quick decision-making. A Lean Factory Operating System thrives on constant visibility into both leading and lagging Key Performance Indicators (KPIs). Yet many companies including large consumer product manufacturers, like Mars, for example, may struggle with integrating the various systems that capture and display these crucial metrics. For years, these companies would have applied Lean visual management practices, but managing a high volume of KPIs manually—often by writing them on whiteboards—is no longer efficient or scalable.

iObeya, a leading platform in visual management, provides businesses with powerful tools to consolidate and share operational data efficiently. One such case involves the integration of iObeya with TrakSYS, a real-time manufacturing execution system (MES) by Parsec, to visualize lagging KPIs. Through a middleware solution like MuleSoft, these systems can be unified to enhance operational efficiency, digitize processes, and centralize KPI management.

Challenges Before Digitizing Lean Factory Operating System: Manual KPI Management and Data Silos

Prior to the integration of TrakSYS with iObeya, organizations faced several challenges:

Lack of Real-Time Visualization

Operators lacked a direct line of sight into lagging KPIs, which were often updated manually or delayed, preventing them from making informed decisions in real-time. For example, some teams managing large sets of KPIs faced significant delays as they waited for updated metrics, which limited their ability to respond quickly to production issues.

Double Data Entry

Many organizations found themselves inputting the same data multiple times into different systems, a time-consuming process that introduced potential errors. Operators who had to manage KPI calculations manually with custom Excel spreadsheets, spent considerable time updating each KPI formula and recalculating values whenever task counts changed, leading to additional risks of miscalculation.

Disconnected Systems

Manufacturing operations often relied on various control systems, like PLC ControlLogix, that were not effectively communicating with the factory’s management software. This created silos and inefficiencies that hindered a clear view of performance metrics like the Top 5 machine breakdowns, which were crucial for maintaining smooth production flows and inventory alignment

Fragmented KPI Reporting

Without a unified platform, KPIs were scattered across different systems, making it difficult to get a consolidated view of the factory’s performance. Operators handling high volumes of KPIs noted that inaccurate or inconsistent data could misrepresent productivity levels, which in turn could affect production schedules and inventory levels.

These obstacles hindered the ability to digitize the Lean Factory Operating System, reducing the potential of automation and continuous improvement initiatives.

Solution: Integration of TrakSYS with iObeya for Real-Time KPI Updates

The solution to these operational challenges came in the form of an integrated approach between TrakSYS and iObeya. This integration allowed organizations to digitize the Lean Factory Operating System by providing a seamless flow of data from the factory floor to the visual management platform.

Key Features of the Integration :

Real-Time KPI Updates

With TrakSYS feeding data directly from factory machines, lagging KPIs were automatically updated every 15 minutes. This eliminated manual data entry and gave operators up-to-date insights into performance metrics. For companies with a high number of KPIs, like Mars, this frequency of updates met their need to access accurate, real-time performance information down to individual operators’ boards—keeping the team aligned on production goals.

Middleware Connectivity via MuleSoft

MuleSoft, acting as middleware, ensured seamless data conversion and mapping between TrakSYS and iObeya. This step enabled communication between various factory systems, such as PLC ControlLogix and OPC Servers, through a standardized API interface, reducing manual data handling and potential errors.

Digitization of Key Processes

Alongside KPI reporting, TrakSYS offered tools for managing EMS/QMS processes, including calculating lagging KPIs and scheduling leading KPIs via digital forms. This digitization further streamlined the operational workflow, giving operators easy access to current KPIs without needing manual spreadsheet updates or extensive custom calculations for each new task.

Reusable API Interface

The API interface used for this integration was reusable and had already been successfully implemented in factories in the Netherlands, China, and Canada, making it a proven solution. Standardizing the interface also allowed for easy scalability across locations, saving time and resources when expanding the integration.

The Operational Impact of Centralized and Real-Time KPI Reporting

By integrating TrakSYS with iObeya, businesses realized significant benefits:

Centralized KPI Reporting:

The integration centralized both leading and lagging KPIs into iObeya, consolidating them into a single visual management platform. For operators managing large volumes of KPIs, this allowed for a simplified view of performance metrics that was easier to access and interpret. It provided teams with immediate insights, reducing the need for manual tracking and minimizing the risk of error due to outdated or incomplete data.

Improved Operational Focus:

Operators could now concentrate on managing actions rather than being bogged down with double data input and complex manual calculations. They no longer needed to rely on custom spreadsheets for KPI calculations, which often required ongoing adjustments and error checks. With real-time updates from TrakSYS, operators could make decisions with confidence, knowing that the data reflected current performance levels accurately

Enhanced Collaboration:

This project involved a wide range of stakeholders, including management, supply chain digital teams, internal IT, and external OT partners. Their coordinated efforts ensured alignment between business requirements and technical specifications, leading to a smooth implementation process.

Efficient Implementation: 

The entire integration project was completed in under 12 weeks, a remarkably short timeline for a project of this scale. By standardizing the data flows and KPI updates, it allowed rapid deployment across multiple sites, ensuring that teams in different locations could benefit from the integration with minimal delay.

High-Level Overview of the Integration Steps:

1. Understanding Business Requirements:

The initial step involved gathering insights from management and supply chain digital teams to capture the operational needs. For instance, some teams required high-frequency KPI updates, sometimes as frequently as every hour, to align with their lean visual management practices.

2. Defining Technical Specifications:

Both internal IT teams and external OT partners collaborated to define technical specifications and coordinate globally. They worked to ensure that the system could handle a large volume of KPIs across multiple departments, minimizing the need for manual KPI recalculations.

3. Middleware Configuration:

MuleSoft was configured as middleware to facilitate data conversion, mapping, and communication between factory systems (such as PLCs and OPC Servers) and iObeya.

4. iObeya Support: 

The iObeya team provided both functional and technical support to configure the platform for visual management.

5. Deployment and Testing:

Following development, rigorous testing was conducted before deploying the solution to multiple factory locations. This step ensured that KPI reporting, and data flows functioned consistently across sites, allowing teams to replicate the integration successfully in each new location.

Digitizing Lean Operations with iObeya: A Scalable Solution for Manufacturing to Achieve Operational Efficiency

Integrating TrakSYS with iObeya provided an effective solution for visualizing KPIs, streamlining operations, and enabling real-time decision-making across manufacturing teams. By digitizing key processes and eliminating data silos, businesses could enhance their Lean Factory Operating Systems and improve overall efficiency. Operators and Lean managers , even those with decades of experience in manual KPI management, saw the advantages of automated, accurate KPI tracking, which reduced errors and saved time otherwise spent on manual calculations.

The integration has already proven successful across multiple regions—from China to Canada—offering consistent, real-time data for operators and managers. As more organizations look to modernize their operations, this integration model serves as a scalable foundation for improved operational visibility and efficiency.

Take the Next Step Towards Operational Excellence with iObeya

If your organization is looking to improve operational efficiency through seamless KPI visualization and integration, learn more about iObeya’s capabilities. Book a demo to learn more information on how iObeya can enhance your business processes.

Ready to learn more about iObeya? Visit our Best-in-Class Integrations page to explore how iObeya connects with your existing Lean Manufacturing tools like TrakSYS to streamline your operations. For more in-depth, technical information on iObeya’s integrations please visit our resource center .

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Integrating TrakSYS with iObeya to Improve KPI Visualization and Operational Efficiency in Lean Manufacturing

Challenges Before Digitizing Lean Factory Operating System: Manual KPI Management and Data Silos

Lack of Real-Time Visualization

Double Data Entry

Disconnected Systems

Fragmented KPI Reporting

Solution: Integration of TrakSYS with iObeya for Real-Time KPI Updates

Key Features of the Integration :

Real-Time KPI Updates

Middleware Connectivity via MuleSoft

Digitization of Key Processes

Reusable API Interface

The Operational Impact of Centralized and Real-Time KPI Reporting

Centralized KPI Reporting:

Improved Operational Focus:

Enhanced Collaboration:

Efficient Implementation:

High-Level Overview of the Integration Steps:

1. Understanding Business Requirements:

2. Defining Technical Specifications:

3. Middleware Configuration:

4. iObeya Support:

5. Deployment and Testing:

Digitizing Lean Operations with iObeya: A Scalable Solution for Manufacturing to Achieve Operational Efficiency

Take the Next Step Towards Operational Excellence with iObeya

Want to learn more about the integration? Check out our Resource Center!

Subscribe to iObeya’s newsletter

Experience the power
 and unleash your full potential!

Why iObeya

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Solution by Use Case

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Get to know us

Product

Use cases

Pricing

Resources

Our customers

Integrating TrakSYS with iObeya to Improve KPI Visualization and Operational Efficiency in Lean Manufacturing

Challenges Before Digitizing Lean Factory Operating System: Manual KPI Management and Data Silos

Lack of Real-Time Visualization

Double Data Entry

Disconnected Systems

Fragmented KPI Reporting

Solution: Integration of TrakSYS with iObeya for Real-Time KPI Updates

Key Features of the Integration :

Real-Time KPI Updates

Middleware Connectivity via MuleSoft

Digitization of Key Processes

Reusable API Interface

The Operational Impact of Centralized and Real-Time KPI Reporting

Centralized KPI Reporting:

Improved Operational Focus:

Enhanced Collaboration:

Efficient Implementation:

High-Level Overview of the Integration Steps:

1. Understanding Business Requirements:

2. Defining Technical Specifications:

3. Middleware Configuration:

4. iObeya Support:

5. Deployment and Testing:

Digitizing Lean Operations with iObeya: A Scalable Solution for Manufacturing to Achieve Operational Efficiency

Take the Next Step Towards Operational Excellence with iObeya

Want to learn more about the integration? Check out our Resource Center!

Subscribe to iObeya’s newsletter

Experience the power and unleash your full potential!

Why iObeya

Solution by Use Case

Solution by Use Case

Resources

Documentation

Get to know us

Efficient Implementation: 

4. iObeya Support: 

Experience the power
 and unleash your full potential!