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the client |
| Our client
The client is one of the largest and most diversified specialty metals producers in the world |
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the challenge |
- To facilitate the adoption of “single-piece flow” and “lean” manufacturing principles
- Enhance shop-floor efficiency of manufacturing associates that receive and move material, and schedule and log daily production, and operators of the equipment
- Increase capability of the production equipment by automatic setup and control based on individual/single piece requirements
- Enable retention of historical detailed records of all processes that each piece of product goes through
- Ensure smooth integration of business data, manufacturing data, process data for piece genealogy
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the solution |
- Leveraged highly integrated and automated Manufacturing Execution System (MES)
- Integration and automation of the production control, process/equipment control and process information systems
- Designed and developed Key Control Characteristics (KCC)
- Vacuum induction melt
- Vacuum leak rate
- Vacuum level
- Time to achieve desired vacuum level
- Re-melt
- Average gas pressure
- Time to achieve desired vacuum level (pump down time)
- Average steady state voltage
- Press/forge
- Reheat time [Time in /Furnace]
- Transfer time from furnace to press
- Time on die
- Time while forging
- Stroke force
- Rolling mill
- Bar temperature on selected points in mill
- Temperature as piece enters mill
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the benefits |
- Robust and systematic process implemented for creating, managing and assigning the individual recipes required to run each process and produce each product
- Enhanced ability to develop new products using a systematic and highly automated process to record, visualize and analyze all process data, both by process and by piece, including the ability to drill back through parent piece genealogy data
- Continuous process and product improvement
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