Uses : real cases of Industrial problems

On a production line the repeated micro-stoppages strongly penalize productivity

Here is a series of case studies that illustrate the real problems you can face every day in your activity.

• Searching for and eliminating micro-stoppages on production lines.
• Monitoring waste of raw materials.
• Monitoring in real time operators workstations.
• Measuring the real productivity of the workshop’s equipment.

Case 1 : True Factory Suite  for « detecting and eliminating micro-stoppages »

Objectives :

- Short stoppages (less than 1 minute) are one of the principal causes of LOSS OF PRODUCTIVITY on packaging lines. By their nature, these stoppages are hard to quantify. That is why it was necessary to provide factories with an IT tool that allows them to measure micro-stoppages.

- The client handled a wide variety of products so the system had to be able to adapt to the processing of consumer goods as well as luxury brands in order to be deployed successfully on all the production units in the group

Implementation :

Géniop developed a user-friendly interface (WIFI touch screen tablet, data analyses under Office System…) specialized in measuring micro-stoppages and accessible to personnel who are not specialized in computers (production managers, maintenance staff) by using the True Factory TOOLKIT.

Results :

Thanks to True Factory, our client knows precisely the duration and nature of micro-stoppages.

Today, 30 of the 70 packaging units in the group have ordered the system from Géniop and use it autonomously (Europe, U.S.A., China).

Case 2 : True Factory Suite  for  « monitoring waste of raw materials »

Objectives :

- The waste of raw materials during manufacturing was difficult to estimate because it concerned small quantities and was sporadic. But it does represent a significant cost, financially and ecologically for our client. To better identify the problem the client needed a precise way of measuring waste during the production flow.

Implementation :

- Géniop connected True Factory to the automatisms of the 8 manufacturing lines and developed specific Intranet production charts to enable the client to work with its teams on the theme of “full pot” waste.

- The maintenance team made the necessary data available in the automats.

Results :

- It took 7 days for Géniop to set up the entire project (including 4 days to check the results).

- The client now can consult information updated in real time on the waste of full pots from any computer connected to the Internet.

Case 3 : True Factory Suite  for  « monitoring in real time operator’s workstations »

Objectives :

- During each production phase, the client’s production teams have to fill out forms (productivity, tests, incidents…) in order to provide feedback on their work.

- The project consisted in computerizing this form to accelerate the analysis of the data while reducing the administrative burden on production

Implementation :

- Development of a dedicated interface on Pocket PC and WIFI linked to True Factory.

- Reproduction of all the paper data entry forms on the Pocket PC interface.

Results :

No more entering production times and tests over and over. The production charts are updated and available in real time

Case 4 : True Factory Suite  for « measuring the real productivity of equipment »

Objectives :

- To improve the productivity of his paint lines, our client had set up a manual system for recording stoppages. Unfortunately, the times recorded by the operators represented only 60% of real stoppages on the lines because the entry procedure was too difficult.

- The project’s objective was to obtain an exhaustive vision of all the stoppages.

Implementation :

- Géniop connected True Factory directly to the manufacturing lines in order to detect the stoppages. The operators only need to indicate the duration of each stoppage.

- The productivity results can be consulted on the client’s Intranet site in real time

Results :

100% of all stoppages are recorded. The True Factory system, which is very user-friendly, is well received by operators.