Client Challenge
As part of our dedication to driving Paperless Factory solutions, we have continuously worked with a leading Lawn Tool Equipment Manufacturer to transform its manufacturing process.
Most recently, our client expressed needs to expand the project to implement an advanced Manufacturing Execution System (MES) for their robotic welding systems. The goal of this project was to track production, downtime, and overall equipment effectiveness (OEE) in real time, helping the our client make data-driven decisions that improved efficiency and reduced manual processes.
Our Solution
We designed a custom system utilizing Ignition 7.9 that provided the customer with detailed visibility into their welding cells’ performance, ensuring that every part made, and every instance of downtime was tracked seamlessly, without the need to disrupt processes.
Project Focus Points:
- Custom Relational Database Integration: Using MS SQL, we built a database to capture critical production data such as part counts, downtime events, uptime logs, alarms, and more. This enabled the manufacturer to track OEE metrics like Performance, Quality, and Availability with precision.
- SKU & Cycle Time Management: We provided an interface for managing SKUs, assigning them to fixtures, tracking their cycle times, and maintaining a history of these assignments and times. This ensured the manufacturer could easily track the relationship between products, fixtures, and machine performance without manual paper logging.
- Productivity Visualization: We delivered a virtualized server and thin clients, which powered a kiosk and large-screen monitor for real-time productivity visualization, offering operators and managers instant access to OEE data and production insights.
- Remote Access & Corporate Integration: By integrating the system into the corporate WLAN (Wireless Local Area Network,) we enabled remote users to access production data from anywhere, increasing operational flexibility and oversight.
- Detailed Reporting: The system generated end-of-shift reports, breaking down key OEE metrics such as Availability, Performance, Quality, and Number of Parts
Parts Made per SKU and cell. Reports included hour-by-hour breakdowns, Pareto charts for downtime reasons, and detailed matrices to summarize production performance. A flexible report interface allowed users to generate historical reports, set date ranges, and export raw data for further analysis.
The Paperless Advantage
Our client has transitioned to a more efficient, automated, and paperless workflow with the installation of this new MES System. With Real-Time Data Collection, remote access, and powerful reporting tools, they are now able to make informed decisions that optimize production and minimize downtime. The Paperless Approach eliminates the need for manual tracking, saving time, cutting costs, and reducing errors, while ensuring that all key performance metrics are accessible at any time.
At DSI, we believe in delivering solutions that not only improve current operations but also prepare our clients for future growth, aligning with their long-term goals of becoming a paperless powerhouse.
