CASE STUDIES

AMPI  – BUTTER & CHEESE COOPERATIVE

CHALLENGE:

Modernize/digitize shop floor data sources & systems to achieve PLANT OPTIMIZATION

“The 10in6 system provides the data we need to prioritize the highest impact fixes.”

Bill Swan, AMPI New Ulm – Division Manager

BUSINESS OUTCOMES

With real-team views of production and quality, historical analysis of trends, alerts, automated reporting and more, our client made improvements in many areas across multiple plants.

о Improved OEE by 15% in the first 6 months

о Paper and label cost savings

о Enhanced traceability – individual case labels with date/time stamp

о Reduced give away, resulting in significant savings

о Improved visibility into product quality and variation

о Modernized the factory – making decisions based on information

о Competitive advantage to acquire new private label customers

о Easier access to information in all areas

о Visibility to improvement opportunities to focus limited resources on right issues

“After moving our quality checks to 10in6 it was the first time we had a good view of overpack. We used to write down check results on paper every 30 minutes but had no way to view the data in real time or historically for trends. We now receive real-time alerts so adjustments can be made immediately. This one change has resulted in significant savings.”

Bill Swan, AMPI New Ulm – Division Manager  

CHALLENGES

Reduce losses from giveaway & modernize/digitize shop floor data sources & systems.

Dairy is a small margin business and giveaway (overweight product) impacts the ongoing financial viability of the business. AMPI had no real-time giveaway data, and limited, trending giveaway data, so adjustments were always made after the fact. Production and Quality were essentially run on Excel, with isolated spreadsheets for everything from quality checks and results, to production counts and downtime reasons. They had a lot of data, but it wasn’t networked and the information was difficult to interpret, taking a toll on decision making capabilities.

о Various spreadsheets as sources for information

о Difficult to assemble information to focus improvement

о Limited historical analysis of quality or efficiency issues

“The Automatically emailed reports are great. I can see all the downtime and quality issues, then review with the leads, so we know what to look into and what to watch for during the shift”.

Joey Vogel, AMPI New Ulm – Division Production Manager

SOLUTIONS

AMPI implemented several 10in6 modules as part of their digitization initiative, with the goal of making faster and better-informed production decisions.

о Production Reporting & Efficiency Modules
о Mobile views to monitor the entire plant for quick decision making
о Automated shift, day and weekly production reports
о Process variable tracking and alerting (moisture, salt, etc.)
о Loss analysis by machine, shift, part number, etc.
о Extended ERP/Enterprise Resource Plan to shop floor production scheduling
о Converted demand plan from ERP (JDE) to schedule production
о Delivered electronically to the lines
о Label printing

о On-demand (vs. batch) for better control
о Time-stamped individual labels for each box
о 10in6 Scheduled Checks for paperless quality
о Alerting for quality checks due, out of spec. conditions, missed checks, and more
о SPC charting and history to identify improvement opportunities
о Real Time alerts on product weights and giveaway
о Easy to search history to confidently address customer audit requests

Trend of OEE shows improvement from 43% to 60% during the first three months using 10in6 solutions.

SPC/Statistical Process Control chart plots results of weight checks, with upper and lower limits shown with red lines. This view is available in real-time during the shift, or historically for any time period and can be sorted by line, product, plant area or shift. Alerts can also be sent by text and email if weights are outside the limits.

“We are now data driven; not best-guess driven. Before 10in6, the shift foreman used to put a line on a report about an issue, but we had no idea how big of a problem it was or how much production was lost because of it. Now we prioritize issues based on the impact on production, not how many times we hear about an issue.”

Bill Swan, AMPI New Ulm – Division Manager

The Production Management Tools of 10in6

The Production Tools of 10in6

IMPROVE EFFICIENCY

Production Reporting (OEE)

Andon Calls

Constraint Manager

Real Time

IMPROVE QUALITY

Track & Trace

Visual Inspection

Scheduled Checks

SPC

IMPROVE OPERATIONS

Issues Tracker

Schedule Execution

Attendance & Skills Tracking

Key Supporting Features:

Analytics

THE MOST POWERFUL REPORTING TOOL EVER CREATED TO ANALYZE YOUR UNIQUE DATA

Operator Console

ONE SIMPLE, TOUCH-SCREEN INTERFACE SPECIFIC TO THE NEEDS OF YOUR MACHINE/LINE

Alerts & Alarms

ISSUE ALERTS AND ALARMS BASED ON REAL-TIME STATUS OR TRENDS USING MUTIPLE STREAMS

Real Time

PROVIDE LIVE FEEDBACK ON PERFORMANCE AND GIVE YOUR TEAM TARGETS IN REAL TIME

WANT TO LEARN MORE?

10in6 Inc

PO Box 36021
Talbot Village PO
London, Ontario
Canada, N6P OC4

 

[email protected]

1-519-661-1001

AVAILABLE 9AM – 6PM

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    10% Improvement in 6 Months