45% OEE achieved in stamping press shop in 35 days

OEE Improvment

Introduction

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.

Problem

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.

Solution

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.

  • IDEs collected real-time data from machines and transferred it to IDAP platform, which displayed various factors such as availability, productivity, quality, part count, all types of losses, and cycle time variation.
  • The facility is also provided for the operator to book losses in real time in order to deep dive into the causes of downtime.
  • With the help of IDAP, the machine data analysis reports are available anywhere and at any time to the company which helps in faster decision making.

Result

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.

Used By Leading Industries Around The World

slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
slider
Book A Demo