Projects and Case Studies ...
Largest Dairy in the World!
We were chosen to design and install an Andon / Judoka system for this prestigious client. Consisting of over 35 large displays which show important real-time production information to the production teams, clearly legible up to 100m away.
The enclosures are sealed and corrosion resistant to withstand the harsh, chilled washdown environment. Some displays include internal temperature control, to ensure they operate at peak accuracy and reliability over a wide temperature range.
The system transformed the performance standards of the new production teams. It helped to instantly notify the engineers and line managers of any line stoppages, ensuring a fast and benchmarked response from the Engineering team. This benchmarking helped to ensure that capacity and output levels are the best in the business.
The system is linked to a bespoke cloud PC software and database system, which we designed and created, so anyone in the factory can view the live status of each line. Automated verbal audio alerts stored in the system and created on-the-fly by the software are broadcast over the sound system to ensure immediate awareness to situations, resulting in minimal downtime.
A site Team Leader said ‘We have reduced response times from over 50 mins to under 8 minutes! The system has increased output thanks to drastically reduced downtime. With over 100,000 litres of milk produced every hour, that is a lot of money saved and a very fast Return of Investment’.
M & J Seafoods
M & J Seafoods are part of the Brakes Group / Sysco. This system monitors live actual-versus-target production, with Andon lights and numeric displays which help to improve line efficiency and communicate targets and real-time actual performance to the workforce.
This application posed the challenge of sensing fish fillets in a cold and very wet, salty environment.
This system comprised of IP67 rated sensors, 2 large digital production displays and remote-viewing, internally-hosted software with live data feeds around smaller LCD screens in the factory.
Having live performance data available allows the management team to act on any issues in production well before they become critical. This boosts Customer satisfaction, profitability
and worker satisfaction, as everyone knows that they have an excellent chance of meeting target, with no surprises at the end of the day, when tallies used to be calculated.
Northern Paper Board
One of the UK’s leading corrugated cardboard box producers need to ensure they meet Customers' promised delivery times. They benefit from a live production performance display system, with archiving for analysis and trend prediction.
We produced a dedicate real-time monitoring system for each of the 6 lines, so that operators and management can see at a glance as soon as there are any issues.
‘The displays have paid for themselves, the inter-competiveness of the teams has risen as has the output and efficiency level’ – Senior Management of NPB Ltd.
Run rates vs. Targets & Actuals
A 3 colour display system clearly shows real time performance to all the team, which greatly improves production rates and with the convenience of automated report creation at the end of each shift.
We have helped Cummins improve their manufacturing efficiency for many years, on various projects. This system included the design, manufacture and installation of 4 large digital production boards. Using our FUSION and TITAN range of products, the displays show live information to the shop floor for each engine line.
Information comes from the customer's existing site-wide performance and order system.
Managers can now share instant messages with the team, to share information on any important issues, stoppage information, quality and safety alerts, to help continuously improve performance and reduce downtime.
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