10in6 CASE STUDY
CHALLENGE:
Modernize/digitize shop floor data sources & systems to achieve PLANT OPTIMIZATION
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-time views of production and quality, historical analysis of trends, alerts, automated reporting and more, our client made improvements in many areas across multiple plants.
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Improved OEE by 15% in the first 6 months
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Paper and label cost savings
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Enhanced traceability – individual case labels with date/time stamp
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Reduced give away, resulting in significant savings
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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
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. All taking a toll on decision making capabilities:
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Various spreadsheets as sources for information
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Difficult to assemble information to focus improvement
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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
“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.
Production Reporting MODULE
- Mobile views to monitor the entire plant for quick decision making
- Automated shift, day and weekly production reports
- Process variable tracking and alerting (moisture, salt, etc.)
- Loss analysis by machine, shift, part number, etc.
Scheduled Checks MODULE
Paperless Quality
- Alerting for quality checks due, out of spec. conditions, missed checks and more
- Easy to search history to confidently address customer audit requests
Extended ERP/Enterprise Resource Plan to Shop Floor
Production Scheduling
- Converted demand plan from ERP (JDE) to schedule production
- Delivered electronically to the lines
Label Printing
- On demand (vs. batch) for better control
- Time stamped individual labels for each box
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
“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
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
WANT TO LEARN MORE?
10in6 Inc
PO Box 36021
Talbot Village PO
London, Ontario
Canada, N6P OC4
Talbot Village PO
London, Ontario
Canada, N6P OC4
Send Email : [email protected]
AVAILABLE 8AM – 5PM
