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Film Coating Manufacturer Achieves Higher Productivity with Clear Downtime Data Visibility

 

Precision coatings are applied to a wide range of touch and vision electronic applications including membrane switches and In Mould Decorated (IMD) products, predominantly in the automotive, telecommunications and domestic appliances sectors. 

Challenges

The coating process is very complex. Production machines complete multiple stages to perform different operations, controlled by PLCs. SCADA interfaces also facilitate operator control.

In this environment, machine downtime is not only the most obvious source of production loss, it can have many other knock-on effects such as on output, delivery commitments and quality..

To achieve the high level of productivity and performance required, this film coating manufacturer needed to achieve clear visibility of machine operations, to tackle downtime and gain a better understanding of process performance issues. 

Shopfloor-OnlineTM MOM Software

Capturing downtime events: goodbye spreadsheets

The Downtime moule of Shopfloor-Online MES automatically captures all fault events from the PLCs: machine stoppage, reasons and when it was re-started. Operators can also manually record stoppage reasons in the system when information isn’t available from the PLCs, such as material shortage.

Overall Equipment Effectiveness (OEE)

The OEE software module automatically captures output from the PLCs and detects when a process is running slow, calculating Actual Cycle Times. Shopfloor-Online provides the manufacturer with real-time data of how many meters were produced and the OEE. 

Process performance monitoring

The MES captures live parameters like oven temperatures, tension of rollers and feed rate, allowing operators to see patterns and identify the cause of process performance problems.

Key Benefits

  • Operators have access to real-time information on machine downtime
  • Process engineers can produce historic downtime analysis and performance reports in a few clicks
  • The electronic line logbook has replaced paper-based shift handovers
  • Improvement plans are based on accurate manufacturing data

About

The company is a world leader in coated films.

 
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