Problem:Operations management in this facility wanted to improve machine changeover time rates, and felt that a large "order queue" display could provide the machine changeover operators with enough real-time data to begin collecting the tools necessary for scheduled production runs. Overall equipment efficiency ratings per machine provided the machine operators with real-time feedback as to their performance.
Solution:
This application included a Data Masters LED Display located strategically above each of the three production machine pods. Machine tenders were able to easily determine where they were within a given production run (% complete). With detailed "next" order information from the plants MES system, they were able to bring the required packing materials in a "Just In Time" fashion. Staging the required tooling in anticipation of the order completion reduced machine setup times.
Data Source:
Since data was required from a MES database and GE Cimplicity HMI software systems simultaneously, Ethernet communication was the only choice. ActiveX controls provided the data connectivity path to mine data from dissimilar systems, and present this information in a common fashion on the displays.
ROI:
This application reduced changeover times by 40%. On average, a reclamation of 20 minutes of production time per shift, or 1 hour/day, equated to a net savings of an estimated $7,500/day. This included machine capital depreciation and burdened labor. ROI for these three displays was estimated at 3 days.