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.

Overall improvement in efficiency and decrease in waste
OEE improved from 20% to 58% in the first 12 months
Visibility to improvement opportunities, focusing limited resources on right issues
Improved visibility into product quality and variation

Modernized the factory – making decisions based on information
Competitive advantage to acquire new private label customers
Easier access to information in all areas
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

Management and Improvement staff had no historical data on performance
No factual information on where to focus resources to improve efficiency
All quality checks were done of paper, with no easy to access history
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.

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SPC MODULE

Process Variable Tracking (density, dimensions, temperature, etc.)
Automated charting of variables
Alerting for out of specification results

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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

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REAL TIME MODULE

Real-time displays of production – on phone, PC or large display boards
Alerts for out spec conditions and production issues

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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.