The power of automation on the shop floor

Imagine increasing the run speed of your manufacturing floor by 50%. This is possible through the power of #automation . By switching from a manual system to an automated one, an automotive company experienced an increase in its run speed from 10 spm to 20 spm. Additionally, the company gained accurate performance metrics, real-time visibility and in-depth analysis. These results not only aided the plant in terms of setting new benchmarks for its optimal run speed, but also modernized the facility as a whole. Here’s how Shoplogix assisted the company in achieving this.

Productivity challenges on the manufacturing floor

In an effort to modernize its shop floor, an automotive manufacturing company wanted to establish new standards for optimal run speed, minimize losses due to microstops, decrease scrap and enhance overall equipment effectiveness (OEE).

However, the #manufacturing company faced a significant challenge. For example, one issue pertained to accurately tracking and measuring performance metrics due to a lack of reliable and precise data. Meanwhile, the company’s manual monitoring system lacked a streamlined process for documenting, measuring and monitoring performance. This left room for errors and inefficiencies.

Additionally, operators recorded downtime events on hand-written sheets while others spent a significant amount of time reviewing multiple versions of reports in meetings. The latter team had to rely on outdated information to make decisions, leading to delays and suboptimal outcomes.

• No reliable and accurate data: Manual reporting and tracking led to unreliable data and poor performance.
• No analysis and accountability: Without detailed tracking information and root cause analysis, stoppages and slow response times became the norm.
• No engagement and real-time data: The lack of visibility coupled with outdated information between cycle times resulted in low throughput and OEE.

Smart manufacturing with Shoplogix

By partnering with Shoplogix, the company gained access to a #smartfactory suite of real-time performance management tools that changed its operations for the better. With quick and easy access to accurate and up-to-date information, the company also optimized its efficiency and made informed decisions with confidence. It’s due to the implementation of these tools that the company experienced a significant improvement in their overall performance.

The use of accurate performance metrics through #digitization , for example, helped set new benchmarks for optimal run speed. Within hours of switching from a manual system to a real-time performance management one, Shoplogix identified the optimal run speed on the stamping presses as 20 spm rather than 10 spm.

Since Shoplogix’s Digital Whiteboard solution provided real-time visibility on the shop floor, the company gained visibility into frequent and predictable patterns of microstops during scrap bin changes. For instance, the addition of a conveyor belt on the presses automatically transferred scrap from one bin to another. This helped with improving the overall efficiency of the plant while eliminating manual steps in the process.

As for in-depth analysis on scrap, Shoplogix found out that parts were getting damaged at a point of transfer. This resulted in the production of more defective parts than usual. Shoplogix assisted in eliminating these damaged items by aligning the final conveyor with a stamping press.

• Accurate performance metrics: The switch to an automatic system allowed for real-time performance management.
• Real-time visibility: Visibility on the manufacturing floor allowed operators to be engaged and accountable.?
• In-depth analysis: Finding the root cause of increased defective parts allowed the plant to quickly remedy the issue.

The automotive company underwent notable changes thanks to the help of Shoplogix's smart factory solutions. Shoplogix equipped the company with automation and performance management tools, enabling it to achieve maximum operational efficiency, eliminate losses created by microstops and minimize waste generated from production errors. As a result, the company experienced substantial improvements across its production processes, ultimately contributing to enhanced overall profitability.

Want to turn your factory into a smart factory? Get started by visiting https://shoplogix.com/ .?

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