Our client establishes in 1965, with a long-standing presence for more than 30 years, commit to create a better life and a better world with household electrical appliances. It became the first foundation of the brands’ success in Malaysia. As part of their ongoing commitment to sustainability, our client aim to improves the capability by fully taking implement Smart Manufacturing. This made possible with our service – Overall Equipment Efficiency (OEE) in order increase operational & allow them at a full operation efficiency of their plant’s capacity.
INDUSTRY

Risks

  • Lacked of real-time information
  • Raw materials data is insufficient
  • Production unable to operate at its maximum capacity
 

In the route to implement Smart Manufacturing, they faced some challenge:

  • Manufacturer lacked of real-time information on numerous unscheduled downtimes
  • Raw materials data is insufficient and inadequate production speed.
  • Production team focus on reacting unscheduled downtime, while it delayed operation team to respond at the first time when downtimes happen
  • They faced production unable to operate at its maximum capacity to fulfilled the order demand.

With the team, algorithm is proposed in order to propagation the downtime codes from machine centers to the line. In order to provide the solution that allows our client to analyze their data accurately to see what was impacting critical production and operations. System Platform powered by MES Performance, Edge Computing & Computerized Maintenance Management System (CMMS) are featured in this solution.

The solutions are then used across all the seventeen lines in Phase 1 implementation for the electrical appliances plant. It is possible to access to pertinent information enables plant personnel; to analyze production data, make informed decisions and implement successful solutions with:

1) Operational dashboard enable real-time situation awareness of production OEE and ANDON (Unplanned downtime) to assist in remote monitoring, reporting & increasing productivity by eliminating movement & gathering loss

2) Implement CMMS system to digitalize maintenance process workflow, reduce response time, handle corrective & preventive maintenance and spare part inventory management

3) Implement Work Order Management system to enhance planning and handle ad-hoc re-scheduling of Work Order due to manpower or material shortage

4) Implement work instruction system to ease the training of new operators

5) Integration with Telegram API to enable critical process notification thru a telegram

“Our client is happy with it as they are now able to identify areas for improvements between unplanned downtime, equipment effectiveness, and labor effectiveness. The Japanese home appliance maker can now identify their real-time manufacturing data across the plant in order to drive operational efficiency. Line mechanics are now focus on overall line performance rather than machine or operator-based issues by improving machine operator performance.”