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With a workforce of more than 70 employees, the company was founded several years ago following the merger of two businesses during the pandemic.
In a recent interview with FourJaw, their Head of Operations discussed the challenges they faced in maintaining efficiency on the shop floor and how they leveraged FourJaw's machine monitoring software to achieve remarkable improvements across their machines, processes and working culture.
The Challenge:
Addressing Efficiency and Productivity
Before implementing FourJaw, the company faced growing concerns over their operational efficiency. Management and shop floor workers often relied on gut feelings to assess productivity, making it difficult to identify performance trends or differentiate between good and bad weeks.
Their existing paper-based self-reporting system for downtime tracking fell short of expectations, as employees were primarily recording what they found inconvenient, not necessarily the root causes of downtime.
“When we used a manual, paper-based data collection method, we focused on fixing the most irritating things rather than the issues that are now proven to have caused the most downtime and lost productivity.
Essentially, operators would record downtime reasons based on what annoyed them, not what was truly problematic. Since switching to FourJaw’s automated downtime capture, which prompts operators to provide reasons for downtime as soon as it’s detected, we have gained clear insights into the actual issues”.
The business had realised that the efficiency challenges began 18-24 months ago. Their initial attempts to implement machine monitoring solutions connected to PLC systems proved problematic, requiring excessive time and effort to maintain, particularly when machines were added or relocated.
To address these inefficiencies and boost productivity, the company decided to look for an alternative solution, and after evaluating what was available in the manufacturing analytics space, decided to invest in FourJaw’s machine monitoring platform.
The Solution:
Implementing manufacturing Analytics
In early 2023, the business began a phased rollout of FourJaw's manufacturing analytics system across its production facility, starting with five machines. The full implementation, covering 25 machines, was completed by late summer 2023.
Before long, it was evident to the management team that FourJaw’s real-time data collection capabilities were able to provide the insight and visibility they had been missing for so long, including invaluable insights into machine uptime and downtime, leading to data-driven decision-making across the organisation.
The results were nothing short of impressive: the Head of Operations explained that they reported a 30% increase in machine uptime and a 10-15% boost in overall productivity. This newfound transparency shed light on previously unnoticed inefficiencies, enabling the company to make targeted adjustments.
The Results:
Data Insights drive focussed Improvements
FourJaw’s platform provided the management team with a wealth of data that transformed how they viewed their operations. For instance, the team had long assumed that tooling issues were a primary cause of downtime. However, the data revealed that this assumption was incorrect, as tooling was rarely the cause. Instead, the monitoring system highlighted more significant challenges, such as swarf management and over-reliance on certain employees to assist others.
Waste Elimination and Process Optimisation
The company also uncovered staffing miscalculations and skill gaps among operators. Two downtime causes stood out: operators helping others and a lack of cross-training, which left the shop floor vulnerable when key employees were absent. This prompted the business to implement more rigorous training and sign-off processes, improving the flexibility of its workforce.
Additionally, the data helped streamline supplier management by tracking downtime caused by supply chain issues. This allowed the company to address delays and inefficiencies more proactively, something extremely important to get right as a supplier to Tier One aerospace manufacturers.
Workforce Engagement and Cultural Shift
While FourJaw delivered immediate operational benefits, the cultural transition was not without its challenges. Some of the longer-serving employees were initially resistant to the idea of machine monitoring, fearing it would be used to scrutinise individual performance. To address these concerns, the management team emphasised through clear communication that the system was focused on machine performance rather than evaluating operators.
Over time, this strategic communication helped shift the company culture toward data-driven decision-making. With performance issues addressed objectively through FourJaw’s data, the business was able to foster a more collaborative and transparent environment. The company also improved cross-training, ensuring that resources could be deployed flexibly across the shop floor, reducing the impact of employee absences on productivity.
Conclusion
This article provides a real-world example of a successful implementation and is a testament to the power of data-driven insights in manufacturing.
By addressing inefficiencies, eliminating waste, and fostering a culture of continuous improvement, this aerospace manufacturer has significantly enhanced its productivity and operational resilience.
The company’s story highlights the importance of embracing technology to stay competitive in the ever-evolving aerospace supply chain and as the company and its people continue their journey of operational excellence, its experience serves as a compelling example of how digital technologies like FourJaw can drive lasting organisational change.
