Gemba Walk: Help a production team do the job right the first time and prevent production errors from happening
Increase operator productivity by comprehensively guiding them through complex processes
Reduce human error through easy to follow, interactive instructions that guide your team as they perform their daily tasks
Augment operator engagement through interactive work instructions
Minimize quality defects through automatic in-line quality inspections
Gain visibility into operator performance through real-time data and bench-marking
Increase productivity by tracking the most relevant key performance indicators (KPIs) of operations
Easily visualize costs generated by production errors, rework and scrap.Reduce the cost of poor quality by minimizing rework, scrap and defective products
Initial 2 hour team meeting to discuss and identify cost-saving opportunities
Further 30 to 60 minute one on one sessions with stakeholders to further review opportunities, document and report
Detailed machine evaluations to OSHA 1910 standards
Stop Time Testing
Recommendations for the proper point-of-operation safeguarding methods or devices
Evaluation of electrical and related documentation for compliance to “control reliability” standards.
Recommendations for additional Part fixtures and hand tools to eliminate “hands-in-die” operations
Forklift safety recommendations and machine collision detection upgrades
Recommendations for Automation upgrades to maximize safety productivity
Build and Deploy mechanical machine guarding systems, OSHA and ISO compliant safety controllers, safety light curtains, safety door interlocks, safety laser scanners, safety floor mats
Long and short-term safety strategies to increase productivity while maintaining a high level of operator safety.
Cost = Average time for audit = one hour per machine + required hardware and labor to implement recommendations
Paint a detailed view of your work processes with real-time data from your people and machines.
Provide department, division or plant-wide display of OEE and other KPIs
Partner example 1: https://www.advantech.com/industrial-automation/industry4.0/
Partner example 2: https://www.klipfolio.com/resources/kpi-examples
Work with IT professionals to ensure seamless and secure network interface
Cost = Hourly depending on extent of project + required hardware and labor to implement recommendations
Connect measurement and inspection tools to the lean apps built to increase production visibility and perform faster root cause analysis
Design 2D and 3D machine vision algorithms using standard or custom tools
Acquire and deploy machine vision components: conveyor, lighting, position stages, work-holding, , lenses and filters, cameras, computers
Implement machine vision systems and automated gaging systems, as required
Cost = Hourly depending on extent of project plus equipment
Connect position encoders, speed monitors, pressure and force sensors, temperature, flow, level, load, weight, vibration and humidity sensors to detect and solve issues faster.
Wired or wireless networking of machine sensors, depending on cost-benefit analysis
Upgrade, rebuild or repair existing machine and robot controls, motors, gearing, valves
Partner example: https://buy.advantech.com/Search.aspx?skey=mesh
Upgrade or design new machine controls for discrete manufacturing equipment, batch processing and robotics cells
UL 508 control panel fabrication
Custom mechatronic systems, robots, conveyors, precision positioning stages
Program CNC machine tools, PLC control systems, motion controls and robots
PLCs Supported: ABB, Allen-Bradley, Automation Direct, B&R, Beckhoff, Modicon, Opto 22, Rockwell Automation, Schneider, Siemens, Telemechanique, Weintek
Robots Suppoted: ABB, Adept, Denso, Fanuc, Kawasaki, Kuka, Motoman, Nachi, Omron, Universal Robots, Yaskawa
Commission controls for plant equipment
Reduce unplanned downtime with optimized maintenance scheduling and failure prevention.
Boost Overall Equipment Effectiveness (OEE) by optimizing the production conditions of each machine and process.
Maximize throughput by identifying process bottlenecks, and testing alternative setups without affecting production.
Reduce defects and improve product quality with accurate predictive quality and optimized machine performance.
Reduce time-to-repair and cost-to-repair through accurate issue categorization and alerts.
Reduce unplanned downtime with optimized maintenance scheduling and failure prevention.
Build new revenue streams by providing digital services to customers such as PdM dashboards, optimized maintenance schedules, or a technician dispatch service.
Improve customer satisfaction by sending customers automated alerts when parts need to be replaced or serviced, strengthening your brand, and keeping a competitive advantage.
Screen example: https://www.seebo.com/predictive-maintenance/
Design data collection systems using existing or new controls and sensors
Process / machine concept development
ROI and benefit analysis of new machines or processes
Machine Scope of Work and BOM development
Machine fabrication, Factory Acceptance Testing, installation and startup
Identify required sensors
Qualified installation of all low voltage (less than 120vac) devices) including mounting, programming, testing
Acquire and Deploy ANDON systems
Acquire and Deploy production and quality plant display dashboards
Track step, process and cycle time by product and worker to optimize production.
Monitor process completions in real-time to detect and solve bottlenecks faster
Measure first pass yield and quality defects by product variety to improve product design
Third-party (PLC / CNC) system data: Bring in and visualize data from other systems and data sources. Build dashboards for all of factory data in one easy-to-understand view.
Error-proof your operations and guide production teams as they perform their tasks by Poka Yoke techniques and digital work instructions to guide assembly
Cost based per screen developed
Detailed operator and management training on all solutions provided: how to maintain tools
Kaizen : Provide your team with feasible targets and objective data-driven feedback. Instantly see the impact of your coaching on your operations in real-time.
Sensor, programmable controller, robot and drive setup and maintenance training
Tulip software screen development training for digital work instructions and detailed quality and production reports; Overall Equipment Efficiency (OEE) measurement
Reduce new employee on-boarding costs by not having to allocate a full-time training buddy and speeding up the training process.
Decrease the time and effort required to on-board new employees through self-guided training modules and digital work instructions
Minimize turnover costs through a more efficient training process that speeds up the on-boarding of new hires
Raise new hire engagement through ‘gamified’ training programs