Linespex Case Study

 

Linespex Case Study:

How our Industrial Vision Systems have dramatically decreased major and minor jams. Enabling immediate root cause analysis and the ability to track and see downtime events, leads to a decrease of waste on the production line and increases overall efficiency.

The Client:

A manufacturing top 100 company that has earned a variety of awards across several categories, including environmental sustainability, diversity and inclusion, safety and innovation.

The Challenge: 

The plant personnel could not figure out why they were experiencing a specific problem that led to wasted product and inadequate liquid filling on their production line. If filling levels are insufficient, this can result in under filled product that goes to waste. Although they were capable of locating the problem they could not see why it was happening. This would result in man hours wasted, un-necessary downtime and the insufficient filling of containers which resulted in a loss of product. 

The Results:

The manufacturer consulted with LineSpex to see if we had a solution. We obliged by immediately beginning our software/hardware demo.  Our high speed system was implemented on their filling line slowing them to perform a root cause analysis to see where the problem was stemming from. Shortly after the installation the cause was quickly identified. After exécution of the appropriate changes the machinery was capable of adequate liquid filling with much reduced waste.

Before implementing our Downtime System, there were 671 major jams and 263 minor jams on their production line. After a week of our systems being installed our client saw a significant decrease to only 352 major jams (48% reduction) and 95 minor jams (64% reduction). After the initial success demo installation, we implemented our system on a few more machines in the facility and they instantly saw results in overall efficiency. 

PACK EXPO 2018

Come by the Fortech booth (E-9011) at PACK EXPO 2018 to see their new patent pending Video Event Capture software that can bring intelligence to any manufacturing facility. Whether you are fully automated or run a hand-packed operation.

 

Reducing unplanned downtime on your production line and increasing OEE

 

Whether you’re a manufacturing professional or an aspiring employee trying to reap the rewards of increasing equipment efficiency, you probably cringe when you hear the words ‘unplanned downtime’.

I once spoke to a continuous improvement professional that told us his manager’s Achilles Heel was hearing someone say ‘we had an unplanned stop. “Say that term to him three times,” he joked “and his heart would stop.”

No matter if you’re in charge of efficiency at the plant level or at the corporate level, no one likes to hear that their machines aren’t running efficiently. Most often, however, there are multiple actions that can be taken to improve the machine’s throughput.

On a recent facility walk-through, the individual responsible for efficiency & output showed us their stops and how it was affecting Overall Equipment Efficiency (OEE). This multi-billion international corporation had a system that tracked overall efficiency and showed it on a scoreboard-style display. Prior to our solution their OEE was running at 87%, which for most is superb, but they were aiming for 90% –the standard for their organization

Many facilities tend to place the blame for efficiencies on human-error related issues that were being written off as machine-related issues. But when an organization is capable of the view of a specific issue, they can correctly categorize downtime. A 3% increase in efficiency does not seem like a daunting task but when you take into account that the facility is already quite efficient it seems like an uphill battle that can’t be won.

With the use of LineSpex they were able to assess the set up and provide an integrated machine vision solution to aid in pin pointing the root cause of stops.

Immediately following the implementation of the LineSpex’s solution the manufacturer was able to use the data to employ changes to increase OEE. Part of the issue was upstream machines were running faster than the downstream machines were able to handle, and overtime, caused a jam.

By implementing Linespex’s integrated machine vision solution, it had quickly found a solution that saved the manufacturing plant thousands of dollars within the first week. Resulting in an increase in OEE, making the plant a more efficient and lean running manufacturing facility.

5 Proven Wastes to Reduce Downtime

5 Proven Ways to Reduce Downtime

Choose Adequate Equipment

When purchasing or assigning new equipment, it is important to ensure the equipment you choose can handle the size of the load, line speed, and strain it will be under. Some managers may be tempted to use smaller or cheaper equipment to save money upfront and ignore the Total Cost of Ownership (TCO) of running the equipment. Circumstantially, the higher upfront cost of a certain machine is the most cost-efficient option when considering downtime, maintenance costs, total output, and defective rate of your product. When calculating TCO, remember to include direct and indirect costs (such as lifespan, machine efficiency, setup costs, training costs, maintenance needs, and estimated downtime).

Measure Measure Measure 

One of the biggest metrics to measure in the manufacturing is Overall Equipment Efficiency (OEE). Once you track your OEE, you can take actionable steps to improve it. There are three major ways to increase your OEE: reduce stops (increase uptime), increase speed (performance), and reduce defects (quality).

To track your OEE, you want to measure the following:

Uptime/Downtime: A ratio of actual uptime to the allotted time the machine was scheduled to run

Speed Loss: How often the machine isn’t running at the optimal/desired speed

Quality Loss: The percentage of defects in the production process (products that do not pass inspection).

After measuring the above three, you will be able to decide which one (or more) need to be addressed.

Stop Firefighting

Reactive approaches are not intuitive. Proactively reducing inefficiencies (preventative & predictive maintenance) are being implemented globally, and for a good reason.  Waiting for a machine to stop before replacing something (or conducting maintenance) won’t prevent that issue from happening in the future. Additionally, it is much more inconvenient and costly to relocate personnel or resources to fix an issue at the drop of a pin. This is also known as ‘firefighting’. This duct-tape approach is not sustainable.

We can avoid this by adopting methods of preventative maintenance. Scheduling a time to inspect the machine’s parts and condition, cleaning, lubricating, calibrating, etc. can go a long way. You don’t wait until your engine is smoking before replacing your engine oil – this is the same concept.  If you need assistance deciding when to do such maintenance, the owner’s manual is a good place to start. Reaching out to the machine manufacturer is also a good avenue to learn more. Lastly, sharing best practices with colleagues and other facilities within your organization can create a successful learning process for all those involved.

Calculate Dollar Cost of Downtime

Calculating the true cost of downtime should include value of product loss, minutes (or hours) spent reallocating personnel and the cost of the repair.

This provides a true figure of what unplanned production stops are costing per minute to calculate what is a feasible expense when evaluating solutions (such as new software or technology). New additions to your technology mix should reduce enough cost to pay for themselves within a feasible period. When calculating the return on investment, this is referred to as ‘payback period’.

Communication

Keeping open communication between the machine operators and supervisors/managers is crucial for efficiency. The most successful processes are when the machine operators have a thorough understanding about the relationship between downtime and business profits. This makes operators understand that they play an important role in the success of the process and adds purpose to their tasks.

 

Two workers were hammering on a piece of granite with a sledgehammer. When asked what he was doing, the first worker said, “I’m trying to crack this granite.” When asked the same question, the second worker said, “I’m part of a team building a cathedral.”

~ Ken Blanchard & Donald Carew

Popular use cases

 

Don’t know where to install our system in your manufacturing plant? Check out these use cases from our clients and let us help you reduce waste and unnecessary production line downtime with our state of the art technology. Call Us: 714-688-7986 Email Us: sales@linespex.com

What we do and how it works

With our intelligent downtime system, get to the root cause of  unplanned production stops and why they are happening. Our system is extremely versatile and can be used in almost any application.

Leaner supply chain

 

With the implementation of lean tools, such as our Linespex Premium LSS systems, we can get you on track to a “smarter” more efficient running manufacturing plant. Building a leaner supply chain is key to more accurate lead times, forecasting, greater quality control and less waste. All of which our LineSpex Premium LSS systems can help your company achieve.

Video Credit:LuXo

Video of our new high speed 240 fps camera from real time to slow motion

Watch a video of our new high speed 240 fps camera from real time to slow motion, showing you just some of our cameras capabilities.

Filler Case Study:Top 100 Food Process Manufacturer

 

LineSpex Case Study: How our Industrial Vision Systems are designed to improve the Overall Equipment Effectiveness (OEE) of any manufacturing production line. Enabling immediate root cause analysis and the ability to track and visualize your downtime events, you can save on product waste, decrease product turnover times, and increase efficiency

The Client: A US-Based food manufacturer, featured on “Food Processing Top 100 2017” list, that began operations in the 1800’s now employs over 8,000 people with revenues over $5 billion USD.

 The Challenge: Unplanned production stops were hurting productivity and overall equipment efficiency. The plant personnel could not understand the true cause of the line stops. Although they could locate where the issue occurred and the end-result, they were not able to isolate why it happened and what caused the machine failures result in man hours wasted, product loss and unnecessary downtime. The cost impact was no longer negligible. Management realized that additional technology was needed to eradicate these losses.

Results:The manufacturer consulted with LineSpex to see if we had a feasible solution. The conclusion was reached that they would partake in our software/hardware demo.

On a bottle-filling line, the system was used to perform a root cause analysis for dented bottles. Shortly after installation of the LineSpex vision system the company was able to identify the reason and implemented an appropriate change in the operation to prevent denting; this resulted in a 30% reduction in stops and 2 point increase on this line alone. On a high-speed pouch line, our client saw a significant  increase in productivity in just a few days’ time. After initial demo’s success, we implemented the solution on a few more machines in the facility. All application saw measurable improvements in overall efficiency.

After a highly effective and successful proof-of-concept; our client decided to scale the solution throughout the facility and expand to other locations. We worked with them directly to identify and implement best practices to ensure continuous improvement in productivity across the enterprise.

“After building a new down bottle reject system for the bottle feeder, we used the system to figure out how to improve it by reviewing performance.”

“On line 107 we used it to reduce setup time during change overs by refining our process and utilizing the LineSpex system to do so. The result was a over 20-minute savings on severe changeovers.”

 

Contact: Marvin Kiwan
657-444-5574
marvin.kiwan@linespex.com
(714) 688-7986