When the information systems arm of Group Dekko developed a strategic plan for gathering information about efficiencies, uptime, and downtime in their manufacturing companies, the goal was to create a more accurate database not only for costing, but also for scheduling.
A rapidly expanding group of privately held, independent, and vertically integrated manufacturing corporations, Group Dekko has approximately 1,500 employees in three divisions spread over 22 locations. Their diverse products and services include wire harnesses, insert and injection molding, assemblies, roll forming, powder coating, turret punching, metal stamping and more. The strategy was to test an information gathering system in one company; then, the knowledge and experience gained would be used in applying the system to their other manufacturing arms.
The Information Systems division wanted a networked system that would connect to the stamping division's existing press monitoring system and collect error codes and other pertinent information about a job, such as parts produced. They were looking for an interface developed to gather this information. In addition, they wanted the operator to be able to manually enter error codes if these could not be captured automatically from the press monitoring system. Along with the error codes and counts, the system would need to keep track of uptime and downtime, production time, efficiencies, etc. The monitor would also have to display what went wrong, when, how, where, and store the data for later downloading and analysis.
Choosing a Monitor
The criteria for choosing a networked monitoring system helped determine which unit would fit into Group Dekko's strategy. First, it must have a simple operator interface with an intuitive menu structure that would ensure error-free usage. The information it collected had to include machine OEE (Overall Equipment Effectiveness) or efficiency, as well as production count. Of primary importance would be the acceptance of operator feedback on the causes of downtime.
A few monitors on the market meet these criteria, but there are big differences in cost and ease of use. Also, some systems require operator use of a mouse and keyboard, whereas others have a touchscreen.
The Impax® TSS-6 reporting system automatically runs an uptime and when the system senses a downtime, the operator enters a code indicating the reason the machine is down. Up to 64 error codes, which report back to the network and go into the database, can be plugged in. Then the machine sets up operation again.
There are major differences in reporting software. While some systems use proprietary software, the Impax® TSS-6 interface for pulling up reports and viewing information is easy-to-use Excel, widely familiar to people in manufacturing.
Ease of Use
After thoroughly researching alternative systems, Group Dekko decided to install the Impax® TSS-6. Their operators quickly got used to the new system: Information Systems engineers spent an hour or two training each group of operators. Chris Edwards, vice president of Information Systems, was pleased with the monitors' touchscreens: "The operators don't have to use a mouse and a keyboard. The learning curve is very quick. Within a week, they were up to full speed. We have it on all our shifts."
Impax® TSS-6 is easy to install. Group Dekko purchased a PC server that could run the server-based software. They set the server up and ran the cable to the Impax® TSS-6 to connect it into the network. Then they were plugged directly into the PLC.
"The Bruderer, being a newer machine, had all the electronics in it," Edwards said. "When we went to some of the older machines that didn't have such a sophisticated PLC, we had to put sensors on the machines and hook up to them. We did all that with our in-house maintenance folks. Then, Process Technologies Group just came down for a day to install the Impax® TSS-6s, making sure they were going to work."
With only two connections, the Impax® TSS-6 system is very simple to hook up. One is an end-of-cycle connection and one is an interrupt that will not allow the machine to start until the operator enters error codes.
Better Information Than Expected
Group Dekko decided they needed to have 6-12 months of real-world data to take into account operating peaks and valleys before any changes were made based on the accumulated information.
"Now, we can do more accurate costing," says Edwards. "This has been a huge benefit. We have identified where we have had our products over-costed -- where we weren't taking as much as we thought. We've had it go the other way, too. That's why these kind of tools are so interesting. Many times they help you identify things that you never would have imagined."
For example, operators admitted there were occasional problems at a packaging station, but they were used to them. The Impax TSS-6 showed the problems were causing 30% of the downtime on that machine. The operators had become desensitized; the collected data was a call to action.
Too often, determining the best way to improve manufacturing is haphazard at best. Whether it is upgrading a machine, automating a process, or improving the workforce, the presumptive need for change is often greatly dependent on the good judgment of managers. What monitoring of the manufacturing process brings to the table is the ability to justify an improvement. With real-world numbers it is possible to demonstrate, for example, how much downtime will be reduced, which, in turn, equates to a corresponding sum of money and ensures adequate payback.
Increased Business, Increased Profitability
The bottom line is looking good.
"We're getting additional business because of this and we're getting more competitive on the pricing side. It really helps," Edwards says.
Group Dekko also saw its profits increase, and attributed a good part of the increase to getting better information, allowing them to quote more accurately in a highly cost-competitive market.
The system also helps them to identify products that they should not be running, whether because of the type of machines they have, or the type of product.
Applying Lessons Learned In Stamping To Injection Molding
Additional monitors are in Group Dekko's future.
"Dekko Stamping is our only stamping operation. But we do a lot of injection molding," says Chris Edwards. "Our next step will be to do the same sort of monitoring on our molding machines. We want to let this run for a year or year and a half to see how well it works, then look at the information and . . . we'll try to cost justify this same sort of investment in our molding division."
The Impax® TSS-6 Efficiency Monitor meets industry's need for real-time problem detection and trend analysis. Companies can eliminate job overruns, lost production time, and feed/speed problems. Trends such as products that tend not to be profitable, inefficient machine use, and workers who need to improve productivity can be identified. On the positive side, the monitors enable accurate maintenance scheduling, motivate operators, and allow operators to start preparing the next job at an exact point in the current job's run. Plus, workers don't waste their time reporting -- the system does it.
