Recap: The High-Mix Plant’s Guide to Data-Driven Improvements

Manufacturers have no shortage of challenges right now—especially high-mix, low-volume (HM/LV) shops. Unpredictable operations, rising complexity, and pressure to improve (without solid data) are all creating major roadblocks. But during our recent webinar, we broke down exactly how leading manufacturers are using data to drive efficiency, profitability, and clarity.

Here’s a quick recap.

High-mix plants often struggle to make improvements

In a high-mix environment, no two jobs are the same. That makes capacity planning, quoting, and even basic visibility incredibly difficult. Most operations leaders are left saying:

• “It’s too complex to track.”
• “We’ track utilization, but what's next?"
• “We have all this data, but don't know how to use it to move the needle."

The problem isn’t just a lack of data—it’s a lack of usable data with the right context.

Step 1: Data lays the groundwork

You can’t improve what you’re not measuring. The first step is getting total visibility across your shop floor—across machines, workstations, and even manual or hard-to-monitor processes.

For instance; with Amper, you can:

• Understand capacity with real-time utilization and OEE
• Track every part of production—from assembly to secondary ops
• Broadcast deadlines, log part counts, and escalate issues in real time
• Maximize labor efficiency by identifying training gaps and overburdened staff

Step 2: Context adds the value

Utilization data is a starting point. But high-mix environments need context. So when you tie machine data to jobs and labor, everything changes.

• Tie job performance to machine data
• Layer in labor metrics to uncover actual efficiency
• See if you’re running to standard—and where the gaps are
• Improve quoting, shorten changeovers, and identify CI projects

This is how you go from raw utilization to actionable insights.

Step 3: Connect it all with your ERP

Manual entry slows you down and increases the risk of error. ERP integration bridges that gap—automating data collection, keeping records clean, and giving teams the real-time visibility they need to take action.

What real results look like

This isn’t theory—it’s happening right now:

• Ruland eliminated double entry and empowered floor teams
• SMS increased utilization by 20% and regained 48+ production hours per month
• Aurora saved 1,000+ hours on manual data collection and shifted focus to high-margin work

When data becomes usable and actionable, continuous improvement finally becomes a reality.

Why now?

Tariffs. Reshoring. AI. Generational turnover. The pace of change in manufacturing is only accelerating—and high-mix manufacturers can’t afford to do the same thing they've always been doing.

If you want to scale production, improve margins, and win new business, it's time to act now.

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