CASE STUDY IN ELECTRONICS INDUSTRY

SUPERVISION OF A SEMI-AUTOMATIC CRIMPING MACHINE

CONTEXT

After installing a new crimping machine manually fed by operators, a cable manufacturer wanted to identify and quantify its performance losses. Realizing the full potential of the equipment and defining production speed standards were both critical and urgent concerns.Internal improvement tools could not effectively reach this goal because the extracted data was unreliable and there was a lack of resources to correctly process it. Due to high production speed, they were looking for an automatic performance monitoring system.

CHALLENGES

1-01

Eliminate and automate
time-consuming
paper sticking

2-01

Quantify performance
losses
reliably

3-01

Adjust the rates whose
optimal value is not known

4

Compensate for the lack of
means
to process the data

TEEPTRAK IMPLEMENTATION

Installed within one hour, the PerfTrak system allowed teams to automatically and precisely give information about the duration and root causes of downtimes. The one-day training of teams, done in the afternoon after the installation, made them fully autonomous for subsequent deployments. PerfTrak also allowed the factory to free managers from time-consuming paper-based reporting tasks.

5

Installation of a
pilot system

6-01

Automation of data feedback

7

Standardization of
stopping causes

8-01

Team formation in
one afternoon

RESULTS

The factory could precisely define its average cycle times on every machine and type of product through the use of Big Data. Using PerfTrak on a daily basis allowed the teams to take corrective actions that lead to a production volume ride of 29% within 4 months. Bonus: Transition from paper-based downtime monitoring to the PerfTrak system improved workstation ergonomics (screen at eye level), brought operators greater comfort and reduced time spent on writing.

9

Identification of
production rates

10

29 points of production gain
in volume on the plant

11

Return on investment
in less than a month

12

Increased operator comfort
and reduced entry times

“We noticed a 29% increase of production volume in pieces per hour after installing PerfTrak
on a single machine. This represents more than 19k€ additional revenue per year.”