Projects and Case Studies ...
Largest Dairy in the World!We were commissioned to design and install an Andon / Judoka system for this prestigious client. Consisting of over 35 large displays showing important real-time production information to be seen from 100m away.
Sealed for complete washdown environment with some displays having heater elements fitted, to ensure operation in the chillers.
The system transformed the mindset and performance standards of the newly appointed production teams. I helped to instantly notify the engineers and line managers of 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 cloud PC software, so anyone in the factory can view the live status of each line. Additionally, automated verbal audio alerts can be broadcast over the sound system to ensure immediate response to situations, resulting in minimal downtime.
A site Team Leader said ‘We have reduced response times from over 50 mins down to under 8 minutes! The system has increased output via reduced stoppage time. With over 100,000 litres of milk produced every hour, that is a lot of money saved and a very fast Returen of Investment’.
M & J SeafoodsThe aim of this system was to monitor live actual versus target production, with Andon lights to improve line efficiencies and communicate targets to the workforce in real time.
This application posed the challenge of sensing fish fillets in a very wet and 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 M&J Seafooods management team to act on any shortfall in production well before it becomes critical. This boosts Customer satisfaction, profitability and worker satisfaction, as they know they have a good chance of meeting target, with no nasty surprises at the end of the day, when tallies used to be calculated.
Northern Paper BoardOne of the UK’s leading corrugated cardboard box producers needed to ensure they met Customers' promised delivery times. They needed a live production performance display system, with archiving for later analysis.
We produced a dedicate real-time monitoring system for each of the 6 lines, so that operators and management could see at a glance if there were any issues.
‘The displays have paid for themselves, the inter-competiveness of the team has risen as have the output and efficiency levels’ – Senior Management of NPB Ltd.
Nestle UKRun rates vs. Targets & Actuals
A 3 colour display system clearly conveys performance to all the team, improving production rates and with automated report creation at the end of each shift.
Cummins enginesWe have worked with Cummins 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 was derived from the customer's existing site wide performance and order system.
Managers can now communicate instant messages with the line to detail errors, stoppage information, quality and safety alerts, to help increase performance levels, and reduce downtime.
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