Teknikum began to optimize its production with a data gathering system called Machine Track. From now on, the company can manufacture small production quantities more efficiently.
The Machine Track was first implemented in Teknikum’s rubber mixing factory in Kerava in 2013.
“We started to collect information about the operation of the mixing systems. By measuring the operations, we have reduced the amount of breaks in production and we have really been able to examine the problematic areas in production more closely,” Lean Manager Esko Mäntyharju explains.
As the project was successful in Kerava, Teknikum decided to implement the Machine Track system also in Vammala. Implementation of the system started from the hose department in 2015. Six hose production lines were attached to the Machine Track.
Operators record every operational pause in machine functions in the Machine Track. If the pause is not acknowledged, the machine will not start. This ensures that the reason for the stop is always discovered. The follow up information of the machines and the reasons for any production breaks are displayed for all to see on the information screen on the factory floor.
No new equipment was needed because it was possible to integrate Machine Track’s user interface into the control panels of the production machines. The integration to the program logic of the manufacturing machines was done with OPC technology.
“Machine Track informs us on the reasons the machines stop working and the wait times. Based on this information we can take reparative procedures. With making custom products, the production amounts get smaller and product options increase. To make the production profitable, the change-over time must be short. In this, Machine Track is clearly useful to us. Even though the system has been operational only for little under a year, we have clearly improved the operation time of our machines,” Mäntyharju happily reports.
Visual, daily management improves communications
ARROW Shop Floor Management is an electric, visual daily management system which collects all desired data about production on one screen from production so that it can be quickly analyzed. With the help of the Shop Floor Management, the production personnel will receive up to date information straight from the ERP, Machine Track and Novi. Internal bulletins can also be posted on the screen’s info field.
“The Shop Floor Management system will bring big chances to our internal communications. Previously, someone always had to collect and print the data to be presented from different sources. Issues were discussed with a delay in the monthly information surveys. In the future, all the needed information will be acquired automatically and in real-time for everyone to see. Information distribution will be significantly improved and our operations will be more transparent,” Mäntyharju rejoices.