The Challenge
- Planning and scheduling consume access time and person dependent.
- Handling the number of physical job cards, operator performance, machine capacity utilization and quality check sheets has become more difficult.
- Increasing throughput, quality and machine uptime become challenge.
- Optimizing Scrap and utilities consumption.
Benefits
- Increased OEE up to 30%.
- Quality increased up to 15%.
- Energy consumption reduced by 8%.
- Energy bill reduced by 10%.
- 25 Man power Saved.
- Scrap reduced by 50%.
- Throughput increased by 15%.
- Paperless shop floor - Go green Initiative.
Asset Covered
- Laser Machine.
- Punching Machine.
- Bending Machine.
- Welding Machine.
- Power Press Machine.
- Shearing Machine.
- Drilling and Grinding Machine.
- Painting Booth.
- Compressor.
- Generator.
- Weighing Scale.
- Wire Cutting Machine.
- Assembly Cell.
- Kitting Machine.
HMI / Tab / Digital Logbook Data
- Idle / breakdown reason selection from the machine screen and data capture on real time.
- Setup / Machining / Inspection and Rework data capture on real time.
- Machine prompt to enter reason if actual hours is exceeding standard hours.
- Smart form to capture actual hours against standard hours for each operation.
- Accessibility of Drawings, Jobcard, Machine schedule and CNC program.
- Operator assistance - Call Supervisor / maintenance person.
- QR Code / Barcode based part identification while packing based on dispatch plan.
- Option for Capturing photo of all the parts inside the box with respect delivery note.
- Quality inspection and remark capturing option.
Machine Data
- Production Count.
- Tool Usage Data.
- Energy Parameter - Voltage -P-P / P-N, Amps - R Y B, KW, KWH, PF, KVA.
- Vibration FFT & Magnitude.
- Coolant Level & Temp.
- Fuel & Oil Level.
- Pressure Level.
- Weighing Data.
- Welding Rod Consumption.
- Oven Temp & Time.