CASE STUDIES
ALUMINUM EXTRUSION PLANT
Learn how an Aluminum Extrusion plant used 10in6 to drive improvements to OEE & Quality, plus reduce costly waste
CHALLENGE:
Learn how an Aluminium Extrusion plant used 10in6 to drive improvements to OEE & Quality, plus reduce costly waste
BUSINESS OUTCOMES
This customer improved efficiency in their aluminum extrusion plant using real-time and trended views of production to focus their improvement efforts on the right issues. In addition, alerting for out of specification processes and converting to paperless quality helped the plant decrease raw material waste and streamline customer audits.
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Overall improvement in efficiency and decrease in waste
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OEE improved from 20% to 58% in the first 12 months
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Visibility to improvement opportunities, focusing limited resources on right issues
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Improved visibility into product quality and variation
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Modernized the factory – making decisions based on information
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Competitive advantage to acquire new private label customers
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Easier access to information in all areas
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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
“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
IMPROVE EFFICIENCY & REDUCE RAW MATERIAL WASTE WITH MORE TIMELY AND DETAILED PRODUCTION INFORMATION
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Management and Improvement staff had no historical data on performance
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No factual information on where to focus resources to improve efficiency
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All quality checks were done of paper, with no easy to access history
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Had an aggressive goal to reduce costly metal waste to 0%
“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
“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
This customer implemented several 10in6 modules as part of their initiative to provide accurate and timely information to focus improvement efforts and reduce waste.
Production Reporting MODULE
- Automated Shift, Day and Weekly production reports
- Real-time alerts and plant displays
- Analyze losses by machine, shift, part number, etc.
SPC MODULE
- Process Variable Tracking (density, dimensions, temperature, etc.)
- Automated charting of variables
- Alerting for out of specification results
Scheduled Checks MODULE
- Alerting for quality checks due, out of spec. conditions and more
- Searchable history to identify trends and drive improvement
- All results available quickly to address customer audit requests
REAL TIME MODULE
- Real-time displays of production – on phone, PC or large display boards
- Alerts for out spec conditions and production issues
Trend of OEE for 12 months shows improvement from 20% to 58%. Improvement in FTT meant the line was stopped fewer times for out of spec issues and rework was also reduced.
Real-time display board showing current shift production and performance against OEE goals. These displays are available on large shop floor monitors, laptop or desktop computers and on phones or tablets.
The Production Management Tools of 10in6
IMPROVE EFFICIENCY
Production Reporting (OEE)
Andon Calls
Constraint Manager
Real Time
The Production Tools of 10in6
IMPROVE EFFICIENCY
Production Reporting (OEE)
Andon Calls
Constraint Manager
Real Time
Key Supporting Features:
Analytics
HARNESS POWERFUL, OUT-OF-THE-BOX REPORTING TOOLS 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
