Practical example
Increased system availability
Using a systematic approach and tool support, we digitized analog data to achieve a sustained increase in the availability of machines and systems that had not previously been digitally connected to the company network.
Background
Following a lengthy insolvency and a change in ownership, our client—one of the largest sand foundries in Europe—faced massive organizational, procedural, and technological challenges. In the first year after the takeover, the company’s strategic realignment focused primarily on stabilizing business operations and, consequently, production. Outdated machinery with inadequate analog data collection (order data, key performance indicators, absenteeism, causes of loss, etc.) and a lack of an optimization process (CIP) made it imperative to achieve transparency regarding production data and control over its analysis as quickly as possible.
Specific task
- Providing transparency regarding equipment data, production metrics, and loss types related to Overall Equipment Effectiveness (OEE), organizational structure, technology, and quality.
- Increasing OEE by reducing organizational losses through the optimization of production organization.
- Increasing OEE by reducing technical and quality-related losses through targeted optimization of machines, tools, and fixtures, as well as an effective error management process.
- Improving efficiency in production control and production processes.
- Stabilizing and increasing plant availability with the goal of reducing the backlog of orders.
KBC's Approach
Ourfirst stepwas to gain a clear understanding of the types of losses occurring with regard to machinery, tools, and fixtures, including their technical condition (damage, performance deficits, and maintenance backlog). To this end, we also documented the actual processes taking place on the shop floor.
Thesecond stepis called “Digitization of Analog Data.” Depending on the situation, a decision is made for each potential data source (e.g., a machine) on how data that was previously unavailable or unusable can be uniformly captured and consolidated manually. This step may involve manual (analog) data or previously unconnected digital data. To this end, shift and order logs were standardized and automated as much as possible. Following extensive training of the production staff, the data collection activities were supervised to establish data transparency as quickly as possible.
Thethird stepinvolved analyzing the data in the KBC Production Monitor (an Excel/VBA-based database), which can be implemented immediately and universally within companies. Thanks to the transparency and detailed insights into losses (in terms of OEE) gained, the project team was able to quickly identify priorities for the subsequent optimization activities. The limited personnel and financial resources were thus used in a highly focused manner for root cause analysis, defining measures, and implementation. Due to the high data quality, hidden correlations—such as those between product quality and the use of tools in certain shifts, or the occurrence of specific types of losses during the production of individual products—could also be uncovered.
Impact achieved
Thanks to our approach and the transparency gained through the “digitization of analog data,” we were able to significantly increase OEE (in some cases by over 20%) in a very short time, thereby stabilizing production. Our customer not only achieved increased equipment availability but also created the necessary leeway to proactively address performance deficits and maintenance backlogs on machines.
Furthermore, the groundwork was laid for thefourth step: efficiency in data collection. By using a KBC “IoT Box,” analog data collection from machines and systems can be retrofitted within days to become a self-sufficient digital system, independent of the existing IT infrastructure—an essential component for the effective and efficient digitization and networking of production data.
