GROTECH Production Ltd are reaping the benefits of their production management software with improved efficiency and productivity.
The Goole contract chemical manufacturer was so impressed by the solutions provided to them by WBSolutions that they not only invested in the software system but also bought the company selling it to them so creating Grotech Data Solutions (GDS).
Grotech Production Ltd (GPL) were keen to drive up productivity and profitability through lean improvements. Top of their target list were the output rate of production lines and line stoppages – both the length and causes of them.
The system designed for them involved capturing and communicating real-time data using tablet, WiFi and Cloud technology to enable operators and managers at all levels of the business to keep track of performance and take immediate action to get it back on schedule should problems arise.
The modular manufacturing management software system devised for GPL consisted of:
• Calculating output rate using a combination of a simple light sensor which detects each filled container plus a raspberry Pi device that converts the data, presents it on a local screen for operators to see and transmits it to a database along with the planned output speed for comparison.
• Recording and monitoring line downtime and stoppages. Manufacturing orders are created in the system containing all the production information required to monitor the line’s activity including such statuses as set up, running and clean down plus a list of possible downtime causes each with their own individual code. Job Control software then captures the real-time status of each order as key data is input on a tablet relating to the various stages of the job. Should a stoppage occur, the beginning and end of the downtime is logged along with the relevant code relating to its cause. Each production line has its own timeline which runs green while running successfully and goes red during a stoppage. This enables the amount of downtime to be easily seen, responded to and analysed.
Some 12 months on from transitioning to the new digital way of working and Overall Equipment Efficiency (OEE) has shown a 26% improvement.
Common stoppages were shown to be related to label changes and delays around the supply of components to the factory floor. In response, GPL:
• increased the number of labels on a reel cutting down the number of changes needed and enabling the lines to run for longer between changes;
• introduced a Bill of Materials software module using a tablet to identify and order the components for each job, booking their transfer from warehouse to line and highlighting in good time any shortages. As finished goods leave the line, they are booked into stock on the tablet, giving real-time progress reporting and up to date information for customers on goods available for despatch.
Getting accurate information in real-time has also helped pinpoint lines running slower than their target speed, prompting managers to find out why and take steps to rectify. With the system able to be accessed and updated from anywhere with an internet connection thanks to the use of Cloud technology, and the software able to be set up for unlimited users, it means everyone has complete visibility of what’s happening within the company at any time.
Unlike most computerised manufacturing resource planning packages, GDS provide solutions based on a modular approach so each customer can put together a software driven management system that works for them. This is much more cost effective, tailored and responsive to the needs of small and medium manufacturers. Want to know more? Get in touch here.
