November 25, 2020
Faulty feed material, which leads to increased rejects, incorrectly adjusted screwdriving processes, which block the workpiece carrier for a long time or handling errors which result in hard module downtimes: Technical, mechanical or organisational problems can lead to numerous cycle time overruns. The STIWA optimization experts bring transparency to the production process and can increase line efficiency by more than 10 per cent within a few weeks.
To solve complex problems in the production quickly, you need immediate cause and effect analyses. STIWA optimization experts help to recognise the complex relationships in production, to uncover problem situations like unstable production processes or low availability and thus achieve a significant increase in the performance of the production. Together with the customer — in an interdisciplinary optimization team of experts from automation, production and analytics — the basics for a comprehensive evaluation and optimization of production will be created.
Data are measured and analysed along the entire value chain, starting from basic manufacturing through pre-assembly to final assembly. Also included are data from processes related to the manufacturing process such as energy, logistics or material. Results are visible in short time: For example in a project with Festo International within a few weeks the IO output of the machine increases by more than 10 % and the reject rates can be significantly reduced. After one year the rate of increase in IO output is already at 40%.
Significant reduction of the machine ramp-up time
There is also a lot of potential for optimization during the start-up phase: With the high performance, scalable and adaptable STIWA analysis tools machine, operating and quality data can already be used in the start-up phase and serve as a basis for optimization measures in performance, availability and quality. Problems and interrelationships can thus be recorded “live”. For example, the cycle time analysis can be used to determine the slowest and thus cycle time determining production module or the one workpiece carrier can be found, which produces problems with certain assembly ‑processes.
The experiences so far confirm the high effectiveness of increasing machine-transparency in the ramp-up phase: for example, the data-supported production start-up at Valeo Wischersysteme GmbH led to a reduction of the cycle time by around 30 to 40 percent. Correspondingly faster the machine was able to produce at planned costs.
The STIWA production optimization experts realize lasting competitive advantages. World and European market leaders as well as hidden champions therefore rely for more than 25 years on the know-how of the STIWA Group.