Factory on Air

Piotr Wiśniewski

Factory on Air is a podcast series that brings you into the heart of modern manufacturing, exploring real‐time data monitoring, predictive maintenance, and AI‐driven digital twins to boost efficiency and cut costs. 

  1. 11/23/2025

    S01:E24: Quality Control and Digital Transformation with DBR77

    Is your quality control an active shield or just an autopsy of failed products? If you are only checking quality at the end of the production line, you have already lost money on materials, energy, and time. Traditional quality control is reactive. In the era of Industry 4.0, the goal is not just to filter out defects, but to prevent them from happening in the first place. In this episode of Factory on Air, we explore how digital transformation turns quality assurance into a real-time, predictive advantage. We dive into how IoT sensors and AI algorithms can detect invisible parameter deviations—like pressure drops or temperature spikes—and trigger automated reactions before a defect is created. Join us to learn: From Detection to Prevention: Why shifting focus from end-of-line inspection to real-time process monitoring is crucial for reducing the Cost of Poor Quality (COPQ).The Role of AI: How artificial intelligence analyzes trends to predict potential defects, allowing you to stop a cycle before damage occurs.Empowering Operators: How digital tools and terminals engage frontline workers in the quality process, giving them the data they need to act fast.Real-World Impact: How the DBR77 platform helps manufacturers reduce quality-related costs by 20–30% within the first year by integrating quality data directly with the Digital Twin. ▶️ Tune in to Episode 24 to stop managing defects and start engineering perfection. New to Factory on Air? Subscribe for your weekly dose of Industry 4.0 insights and practical solutions. For more information on how DBR77 is shaping the future of manufacturing, visit us at www.dbr77.com .

    35 min

  2. 11/17/2025

    Production Planning – How to Avoid Chaos and Delays?

    Is your production schedule an immediate source of chaos? For many factories, production planning is the heart of the operation—and it's failing. Manual schedules in spreadsheets, outdated data on machine availability, and a constant reactive firefight are causing machine downtime, team frustration, and customer delays. In this episode of Factory on Air, we challenge the idea that this chaos is unavoidable. We explore how to move from static, assumption-based planning to a dynamic, intelligent system that anticipates problems before they happen. Join us to learn: Why real-time data on machine load, material availability, and operator status is the non-negotiable foundation for any effective plan.How AI is revolutionizing scheduling by analyzing hundreds of variables to find the truly optimal production sequence—a task impossible for any human.What happens when your plan instantly and automatically adapts to real-world events, like a machine breakdown or a last-minute order change.How the DBR77 platform empowers planners, reducing scheduling time from hours to minutes and cutting delays by up to 40%. ▶️ Tune in to Episode 23 to discover how to make your production plan your greatest asset, not your biggest liability. New to Factory on Air? Subscribe for your weekly dose of Industry 4.0 insights and practical solutions. For more information on how DBR77 is shaping the future of manufacturing, visit us at www.dbr77.com or book a demo here

    29 min

  3. 11/03/2025

    S01:E22 Building the Future of Manufacturing with Modern Technologies

    Modern technologies like IoT, Digital Twin, and AI are no longer "innovations of the future"—they are a necessity for survival today. Companies that want to remain competitive must transform, not just optimize, their operations. While traditional manufacturing is stuck in a reactive loop , modern leaders are building factories that are proactive, adaptable , and driven by real-time data. In this episode of Factory on Air, we explore how these three core technologies work together to create an intelligent system that doesn't just support production, but actively leads it. Join us to learn: The synergy: How IoT provides the data , the Digital Twin creates a risk-free virtual world for simulation , and AI interprets data to recommend decisions before a problem occurs.The real-world results: Discover how companies are using this approach to reduce micro-downtimes by 22% and cut product defects by 17%.The DBR77 difference: How our comprehensive industrial platform integrates all these solutions into one environment, accelerating implementation and reducing risk.Why the ultimate competitive advantage is no longer just capacity, but your organization's ability to adapt.▶️ Tune in to Episode 22 to learn how to stop managing the past and start building your factory's future. New to Factory on Air? Subscribe for your weekly dose of Industry 4.0 insights and practical solutions. For more information on how DBR77 is shaping the future of manufacturing, visit us at https://dbr77.com/ .

    36 min

  4. 10/27/2025

    S01E21: Work Organization in Warehouses – How DBR77 Facilitates Order and Flow

    Delays, picking errors, wasted space, and frustrated employees. These aren't just "warehouse problems"—they are symptoms of logistical chaos that is actively draining your company's efficiency and profits. But how do you fix a system that's in constant motion? Reorganizing a live warehouse based on guesswork is a recipe for more disruption, not less. It's time to stop guessing and start seeing. In this episode of Factory on Air, we challenge the idea that warehouse optimization has to be a disruptive, high-risk project. We explore why the key to order and efficiency is to look at your warehouse through the eyes of data. Join us to learn: How simulation provides a risk-free virtual environment to test new layouts, picking routes, and work schedules before you move a single rack.Why DBR77 is one of the most effective tools for intralogistics optimization, using your real data (from WMS, IoT) to build a dynamic digital model of your operations.How AI-driven analysis helps identify the true bottlenecks, optimize asset allocation, and design a flow that can significantly reduce operation times and boost team satisfaction. ▶️ Tune in to Episode 21 to discover how to move from chaotic firefighting to data-driven warehouse design. New to Factory on Air? Subscribe for your weekly dose of Industry 4.0 insights and practical solutions. For more information on how DBR77 is shaping the future of manufacturing, visit us at www.dbr77.com . Keywords for YouTube/Search: Warehouse Management, Intralogistics, WMS, Warehouse Optimization, Simulation, Digital Twin, Lean Warehousing, Order Picking, Process Optimization, Warehouse Layout, DBR77, Factory on Air.

    32 min

  5. 10/21/2025

    S01:E20 - Optimizing Intralogistics: Milk Run and Kanban

    Is your factory floor plagued by operational chaos, excess inventory, and production delays? The culprit is often inefficient intralogistics. Traditional material handling is a major source of waste, but it's difficult to fix without disrupting operations. In this episode of Factory on Air, we tackle this challenge head-on. We dive into two powerful Lean systems designed to streamline material flow: Milk Run and Kanban.  Milk Run: A structured internal delivery system that supplies multiple production points in one planned route.Kanban: A signal-based system that triggers material orders only when they are actually needed, supporting a Just-in-Time principle.But how do you know which system is right for you? And how do you perfect it? Join us to learn: How simulation allows you to test different intralogistics scenarios—like route frequencies or container sizes —in a virtual environment, all without interrupting live production.Why real-time data is the key to optimizing your delivery routes and Kanban inventory levels.How DBR77 helps companies digitally model their intralogistics , test scenarios , and implement modern solutions that reduce waste and synchronize logistics with actual production needs.▶️ Tune in to Episode 20 to stop the logistical chaos and build a more predictable, fluid, and efficient factory floor. New to Factory on Air? Subscribe for your weekly dose of Industry 4.0 insights and practical solutions. For more information on how DBR77 is shaping the future of manufacturing, visit us at www.dbr77.com.

    40 min

  6. 10/12/2025

    S01:E19 VSM and Machine Load Analysis

    Is your Value Stream Map an outdated snapshot of your factory? Traditional VSM and machine load analysis often rely on averages and assumptions, failing to capture the real-time dynamics of your shop floor. This leads to hidden bottlenecks, unbalanced workloads, and inefficient flow that static charts will never reveal. In this episode of Factory on Air, we challenge the static approach to process optimization. We explore how to transform your VSM from a historical document into a live, breathing view of your value stream. We also dive deep into machine load analysis to uncover the real story behind your production capacity, moving beyond guesswork to data-driven facts. Join us to learn: Why traditional, static VSM is no longer enough to identify the real sources of waste in a dynamic production environment.How to leverage real-time data to create a dynamic VSM that exposes true bottlenecks as they happen.Practical techniques for analyzing actual machine loads to balance your production lines and optimize resource allocation.How the DBR77 platform provides the tools to visualize and analyze both your value stream and machine utilization in real time, enabling smarter, faster optimization. ▶️ Tune in to this episode to stop guessing and start seeing. It's time to bring your process analysis into the age of real-time data. New to Factory on Air? Subscribe for your weekly dose of Industry 4.0 insights and practical solutions. For more information on how DBR77 is shaping the future of manufacturing, visit us at www.dbr77.com or book a meeting .

    26 min

  7. 10/05/2025

    S01:E18 Eliminating the 7 Lean Wastes Using Simulation

    Are the seven wastes of Lean—transport, inventory, motion, waiting, overproduction, over-processing, and defects—silently draining your profits? Identifying them is one thing, but eliminating them without disrupting your live production floor is a monumental challenge. Traditional trial-and-error improvements are often slow, risky, and based on assumptions rather than data. In this episode of Factory on Air, we explore a powerful, modern approach to waste elimination. We reveal how simulation, powered by a Digital Twin of your facility, provides a risk-free virtual sandbox to test, validate, and perfect process improvements before you implement them in the real world. Join us to learn: How to use simulation to redesign layouts, crushing excess transportation and motion waste.The strategies for testing different production schedules in a virtual environment to tackle overproduction and excess inventory.How to identify and eliminate hidden bottlenecks, turning waiting time back into productive time.How the DBR77 platform enables you to run powerful "what-if" scenarios, providing the data you need to confidently deploy changes that have a real impact on your bottom line. ▶️ Tune in to Episode 18 to discover how to de-risk your continuous improvement journey and wage a smarter war on waste. New to Factory on Air? Subscribe for your weekly dose of Industry 4.0 insights and practical solutions. For more information on how DBR77 is shaping the future of manufacturing, book a meeting here: Book a demo

    34 min

  8. 09/28/2025

    S01E17: Simulation of production scenarios

    What if you could test every production scenario before it happens? Stop making critical operational decisions based on intuition and start using data to find the optimal way to run your factory. In a dynamic industrial reality, sticking to a single, rigid production plan leads to inefficiency and missed opportunities. In this episode of Factory on Air, we show you how to move from reactive adjustments to proactive optimization. Discover how Digital Twin simulations allow you to test and compare alternative production scenarios in a risk-free virtual environment, ensuring you always choose the most effective solution. ▶️ In This Episode, You'll Discover: Why You Need Production Variants: Learn how testing different scenarios—like changing the order of operations, shift patterns, or workstation layouts—allows you to adapt to changing demands without risking errors.The Power of "What-If" Simulations: See how you can compare the impact of different variants on crucial KPIs like lead time, resource utilization, and operational costs—all without disrupting your actual production.The Role of Data in Modeling: Understand why accurate data on cycle times, efficiency, and material flows is the foundation for creating reliable simulations and making fact-based decisions.Proven Results: Hear how a sporting goods manufacturer shortened its production time by 15% by testing four layout variants, and how a logistics company reduced packing errors by 40% by simulating a new sequence.The DBR77 Approach: Discover how our platform uses a Digital Twin of your plant to create and test different production scenarios, allowing you to compare KPIs and select the optimal plan before implementation.🚀 Take the Next Step Ready to move from intuition to data-driven optimization? Schedule a no-obligation strategy session to discover how you can test and perfect your production scenarios in a Digital Twin. Book your session: https://meetings.hubspot.com/bartek-straszak About Factory on Air Factory on Air is the podcast for Professional Rebels in manufacturing. We challenge the status quo and provide practical insights for leaders who want to build the factories of the future, today. Subscribe for expert interviews, deep dives into smart factory technology, and actionable strategies to unlock a new level of performance. 🔔 SUBSCRIBE so you never miss an episode! #ProductionSimulation #DigitalTwin #ProcessOptimization #SmartFactory #Manufacturing #LeanManufacturing #ContinuousImprovement #IIoT #DBR77

    36 min
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About

Factory on Air is a podcast series that brings you into the heart of modern manufacturing, exploring real‐time data monitoring, predictive maintenance, and AI‐driven digital twins to boost efficiency and cut costs. 

Information

  • Creator
    Piotr Wiśniewski
  • Years Active
    2K
  • Episodes
    24
  • Rating
    Clean
  • Copyright
    © 2025 Factory on Air
  • Show Website
    Factory on Air