Use case: SmartGlemMan
Automatic identification of components and quality control in the production line
Glem Gas SpA (manufacturing company) and DM Management & Consulting srl (solution provider)
The main objective of the project, which determined the effective supply of the turnkey solution, aimed to meet the needs of management and create a production model that allowed constant monitoring of production efficiency in real time and, at the same time , automate the control of production and activities related to quality control of the components produced.
The goal of the management was to create a new production model that would allow constant monitoring of production efficiency in real time and at the same time automate the control of production and activities related to quality control of the components produced.
Analysis of the state of the art
The process of analysis and study of the production model started with a careful analysis of the state of the art of production, this photo of the production processes has allowed to highlight the critical points and their influence on the production line, with consequent evidence in the inefficiencies and production problems.
Type of products
The company develops, manufactures and distributes appliances for cooking and for the wider world of cooking (kitchens, ovens, microwave ovens, cooktops, hoods, etc.), with distinctive expertise in the development of technology for the production of systems for gas cooking and Bi-energy cooking (gas or electric oven).
Department structure and production lines
The production process is organized into 4 assembly lines (120 work stations) and pre-assembly islands (20 workstations).
From the management point of view, each assembly line consists mainly of:
- a station, where the operator takes care of the pre-preparation and loading of the products that will enter the line;
- a series of assembly stations (with the exception of fixed quality control and test stations);
- control of certain quality stations and test stations, whose position is fixed in each line (but different from line to line);
- end-of-line stations for cleaning the product, canning, palletizing and sending to the storage warehouse.
The process currently provides that the pre-assembly department will carry out the basic structural component preparation phase, the assembly of the kitchen frame and some fixing components.
Output products supply line stations.
Downstream the product is made through a process of assembly along the stations of the line, starting from a first structure that comes in line (“muffle” or the carcass of the kitchen) until you get, after the test, to pay the finished product in the end-of-line station.
The lines of work on a single day shift based on the defined schedule.
The management and controls are delegated to the operators by filling out specific paper documents at the end of the order, which must record the production order, the serial number of the components produced, the transit time on the line, in fixed and fixed points, validate the quality tests (Ok / Not Ok label), and manage storage logistics.
As emerged from the analysis the main theme was to manage in real time and without the intervention of the operator the recording of production times, the transit time of materials, the sequence of kitchens for the assignment of freshmen, the association serial number and result of testing and finally the routing to the storage warehouse and related automatic payment of products in the ERP system.
The prototype model was based on the MES DMP Intelligent Manufacturing System (produced by DM Management & Consulting Srl of Parma), a technological platform that guarantees integration with the factory processes and business processes.
The technological structure of WEB native allows to have a collaborative system and in the same decision on production. The platform has been designed according to MESA guidelines “Manufacturing Enterprise Solutions Association”.
The DMP platform can collect information from the field using various IoTs and manual solutions, allowing production of information to be processed in real time, so that it can be graphically visualized through synoptic tables and specific dashboards of efficiency and productivity indexes (OEE-Pareto-etc .. ).
The project saw the use of RFID components, with storage of the serial numbers and insertion in the production lines of special antennas, in specific points of the line, for the reading of the serial numbers stored in the TAGs and related association of the operator activity.
This first prototyping phase highlighted a careful measurement of the production Lead-time, a precise and timely control of the matriculation / testing.
The activation in the second phase of the no-paper functions, functions that allowed operators to make declarations directly on the touch-screen monitors, allowed a punctual and careful analysis of the operational situations in real time, with consequent evaluation of the corrective actions to be carried out from the perspective of continuous improvement and maximization of production.
RESULTS OBTAINED BY THE NEW PRODUCTIVE MODEL
Operational tests have shown that the new business model allows:
- efficient traceability of the product at every stage of the production process;
- real-time management of the final data of the lead-time with the preventive data;
- creation of the efficiency and productivity control system (OEE, standstill analysis and pauses, Pareto of inefficiencies);
- rapidity in directional decision making when negative events occur;
- productivity recovery thanks to the reduction of the declarative time of the operators (about 82% of the unproductive time);
- reduction of the WIP.