More effiency for the production
of technical polymer products
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 robust, red-brick building in Sastamala, Vammala, has been the birth place of rubber products since the 1950’s. The current owner, Teknikum, has produced polymer products there ever since 1989.
Within the Nordic countries, Teknikum has grown in to a large polymer technology group which has a product range that includes products meant for protection against wear and corrosion, industrial hoses and their installations and technical rubber, plastic and polyurethane products.
Besides improving their own products, Teknikum tailor makes products based on the needs of individual clients. Teknikum has thousands of items in production. The Vammala factory is specialized in the production of mould products, industrial hoses and different polymer products. The factory in Kiikka makes rubber coated metals, mould products and PU products. Rubber mixtures are developed and produced in Kerava.
Influenced by references
Lean manager, Esko Mäntyharju, says Teknikum needed to improve their production efficiency. This is why the group decided to acquire information on suitable management systems to increase production efficiency.
“We went to see a few companies that use the ARROW Machine Track system in their production and we saw the system really could influence production times. Hearing user opinions was significant for us,” Mäntyharju comments.
The Machine Track was first implemented in Teknikum’s rubber mixing factory in Kerava in 2013. The results were promising.
“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,” 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.
Machine Track was integrated into control panels
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.
Also Novi-maintenance system introduced
At the beginning of the 2016, Teknikum began using the ARROW Novi management system. A register of all the machines in the Vammala factory has been created into Novi. The maintenance history of all machines can be recorded in it. Maintenances can be managed and error reports given through Novi. With the help of Machine Track, Novi receives information on the maintenance response times. Teknikum’s 8 person maintenance team can conveniently use the system on a tablet.
“With Machine Track’s help we are moving from time based maintenances to operation based preventive maintenances. Now we have done maintenance work at set intervals even though the operational times haven’t been up. By changing to maintenances based on operations, we can avoid unnecessary maintenances and this means savings for us,” Mäntyharju says.
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.
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“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”
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