Factory on Air

Piotr Wiśniewski
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  • EDUCATION

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. 2D AGO

    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

  2. SEP 28

    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

  3. SEP 21

    S01E16: Digital Twin Factory Planning and Simulation

    What if you could run your new factory for a year before the first brick is even laid? Stop making multi-million dollar investment decisions based on static blueprints and start testing your future operations in a risk-free virtual world. Costly design flaws—from unbalanced lines to cramped logistics spaces—are often discovered only after a new plant is already running, forcing expensive and disruptive changes. In this episode of Factory on Air, we show you how to avoid these mistakes. Discover how digital twin simulations allow you to design, test, and optimize your new factory layout before construction begins, saving you millions and ensuring efficiency from day one. ▶️ In This Episode, You'll Discover: The High Cost of Bad Design: The most common and expensive mistakes made during the factory planning phase, including unbalanced production lines, inefficient logistics, and poor ergonomics.Your Virtual Sandbox: How Digital Twin simulations allow you to test different layouts, model material and people flows, and identify potential bottlenecks before they become costly physical problems.Designing with Data: Why using operational data is the foundation for a 'tailor-made' factory that is perfectly optimized for space, ergonomics, and safety, preventing both cramped conditions and wasted area.Proven Results: Learn how a manufacturer saved 1.2 million PLN by using simulations to avoid building a needless warehouse, and how an automotive plant cut its required production space by 20% without losing efficiency.The DBR77 Approach: See how our platform creates a 3D digital twin of your planned factory, allowing you to test scenarios and analyze operational flows to guarantee a successful launch.🚀 Take the Next Step Planning a new facility or a major production line overhaul? Schedule a no-obligation strategy session to discover how you can de-risk your investment and guarantee efficiency with a Digital Twin simulation. 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! #FactoryDesign #DigitalTwin #Greenfield #SmartFactory #Manufacturing #CAPEX #Simulation #Industry40 #DBR77

    39 min

  4. SEP 14

    S01E15: Full Real-Time Plant Analysis

    Are your business decisions based on a complete picture of your factory, or just fragments of old data? Relying on delayed reports means you're always one step behind, reacting to problems instead of preventing them. This lack of a live, holistic view leads to hidden inefficiencies, slow responses, and missed opportunities for improvement. In this episode of Factory on Air, we explore how to achieve total operational awareness by creating a virtual model of your entire plant, updated in real time. We dive into the power of Digital Twins—virtual replicas of your production spaces, machinery, and material flows—that allow you to see everything, as it happens. Join us to learn: Why a complete, real-time analysis of your plant is crucial for rapid problem detection and agile responses to changing conditions.How Digital Twins and integrated data from across your facility can help you visualize hidden bottlenecks that traditional reports often miss.How DBR77 builds a comprehensive 3D model of your plant, allowing managers to monitor machine status, production progress, and material flows live on virtual dashboards.How real-world companies are using this approach to achieve incredible results, like reducing downtime response by 30% and cutting material losses by 15%. ▶️ Tune in to Episode 15 to learn how to make smarter, faster decisions based on what’s happening on your factory floor right now. 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

    57 min

  5. SEP 7

    S01E14: Analysis of the Causes and Duration of Machine Downtime

    What if the biggest source of lost profit in your factory isn't a major breakdown, but the thousands of tiny, unrecorded stops that happen every day?  Machine downtime—from micro-stops to major failures—silently drains your efficiency, delays orders, and wastes resources. Without precise data on why and for how long machines are idle, any attempt at improvement is just a shot in the dark. In episode 14 of "Factory on Air," we turn the lights on. We challenge the idea that downtime is an unavoidable cost and show you how to transform it into your most valuable source of data for continuous improvement. In this episode, you will learn: The 'Micro-Downtime' Effect: Why even stops lasting a few seconds can accumulate into massive weekly losses and how to start seeing them.From Chaos to Clarity: Practical methods for tracking every machine stop and how to classify them for meaningful analysis (e.g., technical failure, changeover, material shortage).Data-Driven Decision Making: How to analyze downtime data to identify your most problematic machines , uncover recurring issues , and move from random fixes to systemic solutions.AI-Powered Insights: A look at how the DBR77 platform automatically records every stop to the second , uses AI to detect patterns , and visualizes bottlenecks on a Digital Twin.Real-World Results: Hear how companies have reduced downtime by up to 30% and boosted OEE by 10%  by implementing these strategies.This episode is an essential guide for any Production Manager or Plant Director who is tired of guessing where their capacity is going and is ready to make decisions based on hard data. Ready to uncover your hidden factory? Our experts can help you build a clear strategy for downtime analysis. Schedule a complimentary discovery call to discuss how you can turn lost time into a competitive advantage. Book your session here: Link #FactoryOnAir #DBR77 #Downtime #DowntimeAnalysis #OEE #ManufacturingEfficiency #LeanManufacturing #SmartFactory #IIoT #ProductionManagement #RootCauseAnalysis #ContinuousImprovement

    44 min

  6. AUG 31

    S01E13: Communication for Maintenance on the Causes of Failures

    Tired of maintenance reports that just say "machine broken"? Vague communication and guesswork don't just frustrate your maintenance team ; they lead to longer downtime, repeat failures, and wasted resources. Every minute spent on the wrong diagnosis is a minute of lost production. In episode 13 of "Factory on Air," we challenge the reactive, "fire-fighting" approach to maintenance. We reveal how to transform vague breakdown alerts into precise, actionable intelligence that empowers your team to fix problems faster—and prevent them from happening again. In this episode, you will learn: The True Cost of Poor Data: Discover how unclear communication directly increases machine downtime and operational costs.From Guesswork to Diagnosis: Learn how to use data—like failure history and IoT sensor readings—to pinpoint root causes in minutes, not hours.The Power of Automation: See why automated reports containing machine data, stop times, and sensor readings are a game-changer for eliminating information delays.How DBR77 Finds the "Why": We'll explain how our integrated platform analyzes real-time data and uses Digital Twin simulations to identify the probable cause of a failure before a technician even arrives.Practical First Steps: Get a simple roadmap to improve communication between your production and maintenance teams, starting today.This episode is a practical guide for every Maintenance Manager and Production Leader who is ready to move from reactive repairs to a data-driven, predictive maintenance strategy. Ready to stop guessing and start solving? Our experts are ready to show you how. We've seen clients reduce their average repair time by 35% after implementing automated reporting. Schedule a no-obligation discovery call to learn how you can achieve similar results. Book your meeting here: Link

    40 min

  7. AUG 24

    S01E12: What if every employee knew what to do? Providing Information to Employees in the Workplace

    What if your production employees knew exactly what to do, why, and how—every second of their work? No more guesswork, mistakes, or downtime resulting from information chaos. Many production line workers still work “blind” – without access to current targets, instructions, or schedule changes. This is a surefire recipe for mistakes that cost real money. In episode 12 of “Factory on Air,” we challenge the old order and demystify the process of delivering data directly to the workplace. We're not talking about complicated technology for technology's sake – we're showing practical tools that unlock people's potential and allow them to do work that gives them satisfaction. In this episode, you will learn: Why access to data is not a luxury, but the foundation of efficiency? Discover how a lack of information leads to disorganization, quality errors, and downtime.How simple mobile technologies are revolutionizing work on the shop floor? See how apps and tablets reduce response times by up to 40% and reduce assembly errors by 30%.What are virtual instructions and why are paper versions a thing of the past? We explain how to replace outdated documents with interactive, multimedia guides that reduce the time it takes to train new employees.How does the integrated DBR77 platform deliver the right information to the right people at the right time? We show you how we combine planning, quality, and maintenance data so that everyone knows what to do.How can you overcome resistance to technology within your team? We share practical steps on how to effectively implement new solutions while ensuring ergonomics and staff engagement. This episode is a practical guide for any production leader who is ready to stop “putting out fires” and start building a transparent system where every employee becomes a co-owner of the result. Listen now and unlock your team's full potential! #FactoryOnAir #DBR77 #Industry40 #Production #ProductionManagement #SmartFactory #DigitalTwin #IoT #MES #VirtualInstructions #ProductionEfficiency #CommunicationAtWork #ProductionLeader

    47 min

  8. AUG 17

    S01E11: Precise Production Planning

    This episode uncovers how manufacturers can transform chaotic, delay-prone schedules into precise, data-driven production plans—so orders ship on time, machines run at optimal capacity, and teams work without the constant fire-fighting. You’ll discover how real-time machine data, material availability checks, and “what-if” simulations turn planning from guesswork into a science. We’ll show the hidden impact of overloaded lines, stock shortages, and unbalanced shifts—and how to fix them before they derail performance. Real-world success stories prove the approach works: A packaging manufacturer cut order lead times by 20%.A heavy industry plant reduced unplanned downtime by 15% with IoT-based cycle-time planning.A cosmetics producer eliminated 80% of sudden stoppages by aligning schedules with component availability.Without a precision planning framework, manufacturers often face: Late deliveries and lost customer trust.Idle machines or overtime caused by poor material coordination.High variability between shifts due to fragmented instructions.Costly re-planning and emergency logistics.Tune in for a step-by-step playbook—from auditing your data sources and building a digital twin to simulating alternative schedules and rolling out AI-optimized plans—that turns production planning into a competitive advantage. 👉 Book a free session with a DBR77 expert and see our platform in action.  📅 Let’s talk: Book a meeting

    1 hr
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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
    18
  • Rating
    Clean
  • Copyright
    © 2025 Factory on Air
  • Show Website
    Factory on Air