Operational Feedback : A Strategic lever for industry
David Rolland – New Technologies expert at Percall Group
What is operational feedback?
Industrials usually rely on global indicators without real visibility into what happens inside processes.
This is exactly where operational feedback comes in: by transforming raw data into actionable insights to drive continuous improvement.
Operational feedback is not just about reporting information. It is a process designed to connect the world of operations (OT: Operational Technology) with information systems (IT: Information Technology).
Its role is to turn data from machines, processes, and teams into actionable insights that improve industrial performance.
Today, most companies know what enters and exits their production line: they know the raw materials coming in and the finished product going out. But what happens in between often remains opaque.
to precise indicators at every stage of the process”
Why is it a key innovation for industry?
True innovation does not lie only in the latest technology or AI but in the ability to intelligently leverage existing data.
Operational feedback is the engine of industrial performance: it helps anticipate problems, optimize resources, and reduce costs. By integrating this information into systems, companies move from a reactive approach to a proactive one, an essential shift to remain competitive.
How does it work in?
The process is based on three major steps:
Secure Data Collection
Sensors, machine states, error histories, energy consumption… These data come from heterogeneous environments and must be reliable.
Analysis and Contextualization
Raw data only makes sense when put into context. For example, an increase in vibrations on a machine may seem problematic, but thanks to the connection with MES, the system knows it’s linked to the material used. No critical alert, no unnecessary downtime
Reinjection into the System
the insights obtained are used to adjust processes, reschedule maintenance, or optimize production rates.
Challenges and benefits for manufacturers
However, these come with challenges. The big one is avoiding data silos and ensuring data integrity, as fragmented or unreliable information undermines analysis.
Operational feedback delivers significant advantages for industrial companies. It reduces maintenance costs by targeting interventions based on reliable, contextualized data. It also improves machine availability by anticipating unexpected downtime, ensuring smoother and more efficient production. By optimizing processes, it accounts for exceptions and real-world behaviors, making the production chain more agile and effective.
Finally, it provides decision-makers with accurate information to guide strategic choices, relying on concrete data rather than assumptions or gut feelings.
Leveraging operational feedback is redefining how manufacturers optimize their operations.