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How we helped the world’s largest two wheeler manufacturer save close to $1 Million

The outcome of E-Forcast data analytics pointed to the root cause of the frequent machine breakdowns. The correction helped save close to $1 million for the plant.

Industry type:
Discrete Manufacturing

Improved OEE by over
5% within 8 Months

Impact

  • Reduced Downtime
  • Predictive Maintenance
  • Accurate Safety Audits
  • A single-platform access for the varied machines

Overview

The client is one of the largest two-wheeler manufacturers and has an amalgamation of legacy and modern machinery on its shop floor. The challenge for them was the frequent breakdowns of machines. As a result, the shop floor contained CNC machines with controllers from Mitsubishi, Brother, and Fanuc, as well as non-CNC machines.

Challenges

  • Failure to recognize the root causes for constant breakdowns and errors led to increased downtime.
  • Failure to accurately predict the tool life of machines resulted in significant losses
  • Inaccurate safety audits result from workers failing to check machinery at the appointed time.

Strategy

  • The machines' connectivity was achieved with zero downtime of machines.
  • Data were collected at around two samples per second, allowing for real-time detection of even the slightest variations. The recorded history of unplanned outages allowed for a more accurate failure root cause analysis.
  • Deployed specialized tool life management solution, which ensured that tool wear was tracked in real time and that alerts were sent out as needed.
  • Provided each employee a tab with QR codes that correspond to the machines; as they approach the machines and scan the QR code, their geolocation and timestamp are recorded, and the information is digitally input into the system for the supervisor to evaluate.

Outcome

  • $ 1 Million in saving from downtime reduction
  • Quality improvement with better tool life monitoring
  • Reduction of average tool change time
  • Elimination of human error in machine safety audits and ease of storage and retrieval of historical records.

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