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Rexam focuses on quality at all European production plants with new software from Lighthouse Systems

 

"A standard view means that we can compare like with like and identify potential production issues at a very early stage."  Rexam Customer and Operations Quality Director

Challenges

Like all can makers, Rexam needs to constantly improve the yield from raw material (steel and aluminium coils). To achieve this, it needs to improve the capability of the plants and therefore to be able to compare the performance and production issues across all 19 European factories. Rexam were looking for a Manufacturing Execution Systems that would enable them to standardise the quality procedures across all 19 plants and chose Shopfloor-Online MES.

Shopfloor-OnlineTM MOM solution

Number of manufacturing plants: 19

Shopfllor-Online interfaces with the ERP and all plant equipment and applications. It brings in one place production statistics, information from individual machines, stock data, maintenance records, staff levels and workflow schedules.

Quality Control & SPC (statistical process control)

The Quality Control plan is held in Shopfloor-Online, operators follow the plan and perform checks as required by the work order in progress which is downloaded from the ERP.

The system detects trends and alarms operators and managers of out of specification / out of control measurements.

Conformance certificates, when requested, can be produced easily and on demand.

Product Traceability

Inventory and usage of material is tracked in Shofloor-Online MOM from raw material to finished goods on pallets.

Downtime monitoring

Downtime events come directly from the machines into ShopfloorOnline giving a complete picture of the procution process.

Key Benefits

  • Real-time visibility on all 19 plants: all quality, stock, production and performance information is consistent and available in one place accessible via a web-based application.
  • Reporting: Role-based views are available to executives, managers and operators.
  • Compliance: ability to produce automatically conformance certificates for customers requiring these (it used to take 30 minutes when done manually); ability to provide rigorous audit trails under 2 hours.
  • Capability: Key process parameters are known and can be compared across plants, helping to drive improvement initiatives.

About Rexam

Rexam is a leading global beverage can maker.

"A standard view means that we can compare like with like and identify potential production issues at a very early stage."  Rexam Customer and Operations Quality Director

 
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