This USD 47 Million Indian company, headquartered in Pune - is engaged in manufacturing of sheet metal components, tools and dies with a capacity of 3,500 tonnes p.a. These products are used for automotive industry.
The company, during its manufacturing process, faced serious concerns on the efficiency of their plant. The plant worked in all 3 shifts and the production achieved was significantly lower than the planned capacity. The management felt that available capacity was underutilized and wanted to have a clear insight on production & the bottlenecks, which might be affecting the production. The company wanted a solution which could be rolled out in the shortest possible span, as the order books were full and customer delivery schedules were tight.
The solution offered by IU is a combination of its IDE with IDAP platform for measurement of OEE in real time. The reason for using IDE is its scalable nature and easy plug-and-play implementation. IDEs were installed on all the 24 presses in the plant and they started providing real-time OEE data immediately. The implementation with awareness training took around 48 hours to turn around the entire plant into a digital plant.
The company started getting measurable improvement on an ongoing basis as various causes which were causing the losses could now be clearly identified & could be worked on. IU’s cloud-based platform comprising of IDE with IDAP platform provides real-time visibility from a physical location. And thus, the company achieved a 45% improvement in OEE, 35 days from the date the decision was made to go digital.