Achieving production time savings of more than 25%
MEDIUM TO HEAVY PRECISION MACHINING AND WELDING
CIRCA 20 CNC MACHINES, INC. DOOSAN, MAZAK AND DAEWOO
IMPROVE NIGHT SHIFT PRODUCTIVITY AND OVERALL MACHINE UTILISATION
KSW Engineering was formed in 1980, specialising in medium to heavy precision machining and welding. They have a commitment to providing high-quality products to their broad, global customer base, predominantly in the Oil & Gas sector.
They recognise, through sound investment in people, technology and plant, they can be a leading subcontractor to some of the world’s most respected manufacturing companies.
To maintain and improve that position, their focus is to remain at the forefront of technological advances, whilst also anticipating and meeting the demands of the market, and we’re delighted that they chose FourJaw's machine monitoring solution to do just that!
- Night shifts were less productive than day shifts
- No overnight manager to cover shopfloor
- No way to understand the origins of the problem
It was found that the newly established night shift activities were significantly less productive than the day shift operations at KSW Engineering.
Machines which run the same components day-in day-out and had been a staple part of the company’s product line for many years were suddenly hitting problems. With no overnight manager cover of the shopfloor – a role performed by a chargehand — it was difficult, if not impossible, to determine the origins of the problem.
MACHINE DATA MONITORING IDENTIFIES LOST PRODUCTIVITY
The firm decided to extend the use of FourJaw's CNC machine monitoring platform across the factory floor to help identify where the problem was occurring and why.
The operations managers watched with interest the numbers during the first-day shift. Each machine ran like clockwork, with regular uptime and downtime and clear visibility of activity on the machines.
Using the Timeline view in FourJaw's management dashboard, the operations team at KSW Engineering could clearly see that the night shift was underperforming in comparison to the day shift, and the accurate machine data, enabled them to identify why.
A few hours into the night shift, the data showed that an operator was taking twice as long to change over a component as his day shift colleague on one of the machines in the cell.
When asked, the busy operator, revealed that he was performing 100% inspections on all parts to ensure no scrap was produced.
The night charge hand was able to show that by checking 10% of features with the machine stopped he could safely take the part out – provided these dimensions were correct – and carry on machining the next item, completing his inspection report while the machine is running.
MACHINE MONITORING DELIVERS A 12% UPLIFT
This subtle change in operator activity produced an immediate boost to night-shift productivity, going from 34 per cent on day one to 47 per cent machine utilisation on day two and constant from that day onward.
“Overall this has resulted in time savings of around 25-30 per cent on this product line which is a huge benefit moving forward.”
The company has also noticed an additional boost in productivity.
By levelling the playing field of the shop floor, and making performance measurable and visible, FourJaw's platform has provided data insight that has tapped into a competitive streak among machine operators resulting in even higher levels of machine uptime.