Do you know what a 1%, 5% or 30% improvement in OEE could mean to your manufacturing plant?

We always use a simple calculator that gives you an instant and accurate idea of the significant cost savings even a small improvement in OEE can have.

For example, using a fictitious but typical plant with 31 machines. An improvement in machine utilisation of under 2%, a slight reduction in scrap rate and a 1% improvement in cycle rates can mean an annual cost saving of £250.000. This is very easily accomplished with the right information at the right time and the means to easily make any adjustments necessary.

Read here how our customer Hanson Building Products improved their OEE by 20-30%. Contact us info@intouchmonitoring.com or +44 (0) 1604 537100 for more information.

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Guest blog: Production efficiency for profitable manufacturing

PDM Event's Blog

Christina Larsen, Marketing Manager at Intouch Monitoring Limited, explains how using a Manufacturing Execution System (MES) is a simple way for plastics manufacturing firms to increase manufacturing efficiencies and make business more profitable.

Intouch Monitoring Limited will be exhibiting at PDM 2018 on Stand D035.

In manufacturing, profit is reliant on how efficient the shop floor is. Squeezing everything from your resources without compromising on quality is a challenge increasingly faced by manufacturers. So how can manufacturers stay competitive whilst maintaining or increasing profit?

Continuous improvement is key. Looking at existing processes and finding ways of making these more efficient and cost effective ultimately leads to a more profitable business. Without a mechanism that collects accurate data and standardises current systems, continuous improvement is often reactionary, where problems are only dealt with after they have become costly and problematic.

Making sure that you make optimum use of your resources…

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Industry 4.0 and profitable manufacturing

In manufacturing, profit is reliant on how efficient the shop floor is. Manufacturing Executions Systems gives manufacturers the tools to easily make Continuous Improvement decisions that lead to increased profit.

According to a recent survey by the Confederation of British Industry, small British manufacturers reported the fastest rise in new orders since 1995 and are more optimistic about the year to come.

“Growth is going strong for SME manufacturers, who are reaping the benefits of a lower pound and buoyant global growth – as seen in record expectations for export orders growth,” CBI economist Alpesh Paleja wrote.

However, he added that firms said their margins were still under pressure, with cost pressures high, and that businesses expected to raise prices further.

In manufacturing, profit is reliant on how efficient the shop floor is. Squeezing everything from your resources without compromising on quality is a challenge increasingly faced by manufacturers.

So how can manufacturers stay competitive whilst maintaining or increasing profit?

Continuous improvement is key. Looking at existing processes and finding ways of making these more efficient and cost effective ultimately leads to a more profitable business. Without a mechanism that collects accurate data and standardises current systems, Continuous Improvement is often reactionary where problems are only dealt with after they have become costly and problematic.

Making sure that you make optimum use of your resources by installing a Manufacturing Execution System (MES) is a quick, easy and cost effective way. Intouch real-time scheduling, monitoring and reporting system gives manufacturers the visibility to easily make Continuous Improvement decisions that:

  • Improves OEE (typically by up to 30%)
  • Improves productivity
  • Reduces lead time
  • Decreases production errors
  • Increases production throughput
  • Raises quality and simplifies compliance to industry standards

 

How can Intouch MES improve your profitability?

By Monitoring

Being able to monitor production in real-time and having live and up to date information in any part of your factory removes the costs and errors of collecting production data manually. This enables your personnel to use their time more efficiently and the high visibility also motivates production staff to keep machines operational.

With Intouch, key performance figures such as output speeds, run time, down-time, good/scrap production and utilisation are graphically displayed on fully configurable and tailored diagrams which can be seen at a glance. Operators can interact with the system through individually customised keypads at the machine or our new wi-fi option gives users the freedom to connect from any screen. This allows action to be taken to rectify problems as they happen and leads to much faster response to stoppages which results in less waste.

By Scheduling/Planning

Intouch has an easy to use live scheduling module which shows the progress of every job in the plan. The Gantt chart view provides a graphical visualisation of machine loading and capacity utilisation. Jobs on the chart can be highlighted for many reasons such as tool changes, late jobs or resource clashes and takes shift pattern, planned maintenance, overtime and shutdowns into account.

Rescheduling is easily achieved through a simple drag and drop operation which can be forward or backward scheduled to highlight spare capacity. Better planning significantly reduces changeover time and the job schedule view gives details of each job enabling operators to prepare for up-coming tool changes.

By Reporting

All data collected is automatically and accurately stored and made available through the Intouch reporting module. Better tracking of actual materials used, increases accountability of material use to individual operators, which generally reduces waste. The data enables informed decisions to be made to streamline operations and monitor key processes to better control final product quality and achieve a “zero defect” policy.

For examples on how our customers have reduced costs, improved OEE and significantly increased profitability through installing Intouch, have a read through some of our case studies.

 

 

Intouch sells you as a supplier

Intouch real-time monitoring, scheduling and reporting enhances visibility and control of the manufacturing process, enabling decisions that significantly improve OEE to be made, which means a reduction in manufacturing costs.

 

What it also does, is help you sell your company as a supplier. The Intouch system means that your customer can be sure of:

 

  • On time delivery
  • Quality assurance (full product genealogy, event history and material traceability guarantee product safety and compliance to regulations)
  • Competitive pricing as you pass your cost savings onto your customer (without compromising on quality)

 

Website traffic to our Intouch website from our customers websites (the ones who have Intouch on their websites) shows that customers are interested in the product and what it means to them. As Dave Sheridan from OnePlastics said ‘One of our blue chip suppliers told us that Intouch gave us the point of difference between other suppliers’.

 

For more information on Intouch’s easy to use, affordable and flexible systems, download our brochure, newsletter or contact us for more information or to book your demo.

Understanding what MES (Manufacturing Execution System) can do for you…in layman’s terms

I was hired as a marketing consultant by Intouch at the beginning of June. As a novice in the plastics industry I asked a lot of questions and I started to understand the system.

I quickly learned by talking to John (Intouch director) and Andy (Intouch sales manager) and reading through our customers reviews that if you install a system in your factory, it allows managers to see what’s going on and lets them make decisions which leads to making the factory run more efficiently. And that means that they can make more products with the same assets, make better use of the machines, improve the quality of the products, reduce waste, assure quality and so on. I also learned that our customers were more likely to be chosen as a supplier if they had a monitoring system.

So, to me it was a no brainer. Surely every factory must have one of these systems and my job was simply to raise brand awareness and communicate why our product was the one that should be chosen.

Not so, I was told. There are many factories that do not have any form of MES in place. So then I thought it must be because it is expensive. But that isn’t the case. It costs a fraction of the price of a machine or materials and the ROI is often a matter of months. In fact, Simon Anderson from LVS products told John at Interplas the other week that he wished he’d bought the system when he first met John, instead of waiting a few years as it would have saved him over £250K! How many moulding machines could he have bought for that?

Then it must be because it’s difficult to install or complicated to use and learn. That isn’t the case either with Intouch systems. They can be installed quickly, easily and retrospectively and without disrupting the manufacturing process. They are also incredibly simple to use because of the self-explanatory graphics, the drag and drop system, the intuitive scheduling and reporting module and so on, that after a few minutes of explaining by James (Intouch project manager) and Karl (Intouch director and head of engineering) even I was able to use it.

I was lucky to attend and help man the Intouch stand at Interplas and hear first hand about the issues faced by shop floor managers. I spoke to a shop floor manager who had originally been against having MES on his shop floor, but then after using Intouch for a while didn’t know how he’d coped without it.   He now works for a new company and the first thing he wants to do is install Intouch in one of the UK factories he’s responsible for and then ultimately in all of them, spread all over the world.

If you’d like to learn more about Intouch monitoring, planning and reporting systems, please contact us and it will be our pleasure to send you information, arrange to visit you, arrange a demo or take you to a plant to show you the system in action.