Why Plants Still Run on Spreadsheets, and Which Ones to Replace First
Why factory spreadsheets survive, a one-week inventory to find the ones that matter, which to replace first, and how to retire each one safely.
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Knowledge base
Practical articles for plant teams
Articles on measuring OEE, running maintenance, closing quality issues and using data on the shop floor. Written by the DBR77 team.
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9 articles
Why Plants Still Run on Spreadsheets, and Which Ones to Replace First
Why factory spreadsheets survive, a one-week inventory to find the ones that matter, which to replace first, and how to retire each one safely.
- MES Production
- Tasks
- KPI / Analytics
How to Review and Scale IRIS After the First 90 Days
A 90-day review of IRIS in six areas, a clear scale, fix or stop decision, and a template for copying a working setup to more lines and plants.
- KPI / Analytics
- Tasks
- Data & AI
How to Roll Out IRIS Module by Module Without Disrupting the Plant
Roll out IRIS in waves: one pilot line, one or two modules, a parallel run and written go criteria. A module order and success measures that keep lines running.
- MES Production
- KPI / Analytics
- Tasks
How to Build a Business Case for a Plant Operating System
Build a plant operating system business case from your own baseline: measure the losses, value them, count the full cost and set a break-even a pilot can prove.
- KPI / Analytics
- MES Production
How to Evaluate a Plant Operating System: A Buyer's Checklist
Compare plant operating systems on your own scenarios, not feature lists: eight criteria, demo questions and a scoring method for COOs, IT and purchasing.
- MES Production
- KPI / Analytics
- Data & AI
How to Unify MES, WMS, QMS and CMMS Without Replacing Everything
Unify MES, WMS, QMS and CMMS without a big-bang project: shared master data first, then key events, and replace a system only when it blocks the flow.
- MES Production
- WMS
- QMS
The Real Cost of Siloed Systems and Spreadsheets in a Plant
Siloed tools and spreadsheets cost a plant in retyping, reconciling, late signals and quality escapes. Where the cost hides and how to measure it in two weeks.
- MES Production
- WMS
- KPI / Analytics
Plant Operating System vs MES vs ERP: Who Does What in a Plant
ERP plans the business, MES runs production orders, a plant operating system runs all plant work on one record. Who does what, and where MES stops.
- MES Production
- CMMS
- QMS
What Is a Plant Operating System? A Plain Definition for Plant Leaders
A plant operating system runs production, maintenance, quality and warehouse work on one data model and turns signals into owned tasks. Here is how.
- MES Production
- Tasks
- KPI / Analytics
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