Cases – Ectron Corporation

DRY BOXES

Issue

Pharmaceutical company uses dry boxes in its operation. However, company wanted independent verification of the dry box readings, as well as independent verification of no door opens during the cycle. Moreover, operators wanted real-time, remote alerts when the cycle was completed, and to be able to check availability before going back to the lab.

Solution

Dry boxes were instrumented with environmental sensors and door open sensors. App requires operator to log each run.

ROI

Company was able to independently verify the conditions inside of the dry boxes, as well as the fact that the doors remained close during the cycle. Moreover, company was able to complete more projects on or ahead of schedule with notifications regarding dry box availability going to the entire team whether inside or outside of the lab.

Outcome

Certification records created and production schedule met or exceeded rate up 21%

PCB BURN-IN OVEN

Issue

Manufacturer wanted to confirm minimum time required for burn-in is followed every time without ‘door opens,’ which was causing failures.

Solution

Burn-In Oven was instrumented with environmental sensors and door open sensor. App requires operator to log each run.

ROI

Manufacturer learned that minimum burn-in time was actually over an hour less than initially thought required if door remained closed the entire run. So, manufacturer was able to decrease burn-in time, which sped up completion and reduced energy consumption. Manufacturer was also able to track door opens that contributed to board failures.

Outcome

Decrease in product waste, energy usage and production time

CNC Machines

Issue

Gear manufacturer had both new and old CNC machines. Some machines were working better for certain products than others. Moreover, the older machines had substantial downtime for repairs.

Solution

CNC machines instrumented with industrial-grade multi-function sensors. Specifically, we added sensors to measure coolant level, spindle/table vibration, type of material used and tool use turnover among other features. Operator alerts were also programmed so that production process and/or machine profile deviations could be corrected in real-time.

ROI

Customer has the data needed to identify and immediately remediate any production or machine profile deviations including vibration profile deviations, incorrect tool mounting, coolant depletion and/or maintenance omissions. Customer was also able to compare output, product quality and energy cost from machine to machine, as well as pinpoint equipment deviations for targeted predictive maintenance and/ or repairs.

Outcome

Decrease in product waste and machine downtime.

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Agri-Drying Equipment

Issue

Agri-company had a large hops-drying bed that was not drying product uniformly.

Solution

We instrumented the drying bed with a dozen industrial-grade multi-function sensors. We also added sensors to measure material temperature and humidity, airflow from fans, natural gas and electricity usage, machine utilization and availability and other KPIs. We also instrumented the area with environmental sensors to track environmental conditions that affect the bed’s temperature and, thus, product quality.

Outcome

Company has data needed to:

Adjust machine settings (incl. fan speed) in “REAL- TIME” to get desirable average temperature across the entire bed;
Adjust controllable environmental factors as needed “during the production run” to maintain ideal conditions;
Test product dryness in REAL-TIME and across the entire bed;
Forecast exact costing per run including natural gas and energy usage;
Pinpoint equipment deviations for targeted predictive maintenance and/or repairs; and
Run simulations to see what changes in the process yield efficiencies.

ROI

Drying time decreased by 4%. Machine warm- up time decreased by 20 minutes.

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Injection Molding Machine

Issue

Injection molding manufacturer had both new and old machines. Some machines were working better for certain materials. The older machines had substantial downtime for repairs. Product output was different from run to run resulting in waste, and the source of the deviations could not be pinpointed.

Solution

We instrumented the older injection molding machines with industrial-grade multi-function sensors. Specifically, we added sensors to measure thermolater flow rate, hopper level, manifold temperature, fluid temperature (to and from the manifold), material flow rate, material dew point, machine utilization and availability and other KPIs.

Outcome

Customer has the data needed to:

Adjust machine settings in “REAL- TIME” to get desired manifold and hopper temperature maintained in every machine;
Compare output and product quality from machine to machine to determine which machines worked best with what materials;
Monitor machine usage for production scheduling and energy efficiency;
Forecast and track per run production cost (including energy cost);
Pinpoint equipment deviations for targeted predictive maintenance and/ or repairs; and
Run simulations to see what changes in the process yield efficiencies.

ROI

Customer is able to reduce waste (product and time), deliver a more consistent product, implement more accurate scheduling and perform preventive maintenance on machines.

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Compressor Monitoring

Issue

Company uses compressors to supply compressed air throughout production facility. Whenever there was a leak in the airflow line, the compressor would run 24×7 and eventually overheat. Company had to replace the compressor 3 times. After the third time, Company installed fans in the Compressor Room to continually cool the compressors.

Solution

We instrumented the Compressor Room with environmental sensors. We also put a temperature monitor in the shell of the compressors. We also programmed SmartEYE™ to turn the fans on when the compressors heat up, and off when the temperature drops.

Outcome

If the Compressor and/or Compressor Room reach a certain temperature, then the fans are automatically started (without human intervention). Once the compressors cool down, the fans turn off. If the Compressor and/or Compressor Room stay at an elevated temperature, email and text alerts are sent to the Facilities Manager and Operations Manager.

ROI

Energy usage decreased 82% due to less compressor usage, as well as less fan usage. The compressor runs less because a simple leak in the line can be addressed quickly, as the data reveals the leak in real-time via elevated compressor temperature. Moreover, instead of the fans running all day, they only run when needed.

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Packing/Shipping Operation

Issue

Logistics company suffering product waste, additional shipping expenses and delays for their customers due to mispacked and/or late packages.

Solution

Using SmartEYE™, we converted the Company’s manual packing stations into SMART packing stations using barcode scanners, RFID tags and LED lamps (to indicate active vs. inactive, manned vs, unmanned). The software on the Smart Packing Stations was pre-loaded with all 4-layers of BOMs that comprised a complete Kit (i.e., a level of customization unachievable by their existing ERP system). The data collected is being fed directly into the Company’s ERP system.

Outcome

Company has SMART packing stations that:

Alert the operators of any mispacked or missing items in REAL-TIME; and
Give managers REAL-TIME confirmation of compliance with packing BOMs and production schedule.

Moreover, integration into the Company’s ERP system provides seamless operational visibility on the production floor to management, real-time updates to inventory stock levels and building ideal profiles relating to operator efficiency (by kit-type, by shift and over time).

ROI

6% increase in productivity; virtually no packing errors. Increase in productivity reduced over-time hours and, therefore, overall payroll and utility costs.

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Computer Manufacturing

Issue

Unexplained production delays
Production meeting information based on floor managers’ opinions rather than empirical data
Late deliveries due to component shortages not timely identified
Sales/Customer Service Department not timely updated on available inventory and delays
No ability to determine worker efficiency

Solution

SmartEYE™ Factory Flow SaaS implemented at facility

Outcome

Ability to identify production schedule compliance and delays including exact source of delays by department, individual, part shortages, machine downtime (as reported from the factory floor) and/or other causes
Sales/Customer Service Department able to see finished goods inventory and production delays per order in real-time
Ability to confirm no component shortages that would suspend a production run before starting a production run
Ability to identify most prioritized and recurring delays and bottlenecks, and put remedial action in place
Workers incentivized to do their best, and over-performing workers rewarded