Profitability Improvement in a CNC Die and Mould shop

Customer:

A leading die and mould manufacturer in Chennai.

Solution implemented:

Embridge custom solution using standard platform for CNCs.

Industry:

Discrete Manufacturing – Die and Mould.

Platform:

MT Connect with requisite MT Connect adapters.

About Customer:

A leading Die and Mould manufacturer in SME sector making complicated dies and moulds using CNC machines.

Objective:

 To accurately identify the reasons for difference between actual machining time and calculated machining time.
 Analyse the reasons and take corrective actions.
 Improve the estimation by adding suitable factor to the calculated time based on analysed data.
 Make improvements in manufacturing process to avoid idle time.
 Provide real time visibility.

Challenges:

 25% to 100% variation between estimated cycle time and actual cycle time .
 Cost over run .
 Delayed supplies and scheduling problems.
 No real time visibility of production data and losses .

Solution and Result:

 Entire machining cycle monitored for running status, cutting time, tools used and idle times .
 Time taken for completing each operation and time taken by tools is captured .
 Data compared and analysed against estimations by CAD system .
 Necessary factors built into estimation process to improve the accuracy in cost estimation .
 Data driven improvements carries out improve productivity.
 Gap between estimated to actual cycle time reduced to 10%.

Traceability Solution for Automotive industry

Customer:

A leading Tier 1 auto component manufacturer, with OEM customers across the world.

Solution implemented:

EmTrace - An Embridge Traceability and Assembly Line solution.

Industry:

Automotive.

Platform / Partners:

We used Open Platform Communications Unified Architecture to enable Industrial Machine to Machine communication. The line was upgraded with Mitsubishi FX5U PLCs where ever required.

About Customer:

A leading auto component manufacturer with substantial exports.

Objective:

 End to end traceability.
 Prevent defective subassemblies from getting assembled in final assembly.
 Provide a productivity monitoring and loss reduction application.
 Provide real time visibility for production and losses.

Challenges:

 Manual Inspection errors .
 Increased reject rate and hence costly rework .
 Increased warranty cost.
 Lack of enterprise wide data visibility .

Solution and Result:

 10% rework to zero rework levels .
 Enterprise wide data visibility made available on Mobile Application and Live TV displays on the shop floor .
 Productivity improvement of 20% achieved .
 End to end traceability with process parameters .
 Data porting to ERP system to eliminate manual production data updation.