computer integrated manufacturing - ams controls · computer integrated manufacturing (cim) •cim...
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Computer Integrated Manufacturing Benefits and Application for the Roll Forming Industry
Jaycen Rigger Director of Technical Services AMS Controls
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Computer Integrated Manufacturing (CIM)
• CIM “integrates production, administrative, and support functions in a manufacturing firm by tying together separate automated systems and minimizing administrative and manual functions.”
• ERP and CRM
• Electronic Flow of Information Related to All Aspects of the Manufacturing Process
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Computer Integrated Manufacturing (CIM)
CustomerSales
Engineering Finance
Production Control
Machine Operator
Maintenance Shipping
Packaging
Bundle Marking
Part MarkingLength Control
Profile Control
P.M. Instructions
THE OFFICE
THE SHOP FLOOR
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Computer Integrated Manufacturing (CIM)
CustomerSales
Engineering
Finance
ProductionControl
MachineController
Packaging
BundleMarking
Part MarkingLengthControl
ProfileControl
P.M.Instructions
Maintenance Shipping
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Benefits of Integrated Manufacturing
1. Mistake-proofing
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Mistake Proofing
Example:
10 orders/shift
5 cutlist items/order
10 keystrokes/item
= 500 keystrokes/shift
99.9% data-entry accuracy rate
= 1 error every 2 days
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Mistake-Proofing
Order Fulfillment
• Ensure Correct Profile, Material, Length, Quantity, etc. Delivered to the Customer When Promised
• Best Practice: Single Point for Data Entry & Verification
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Benefits of Integrated Manufacturing
1. Mistake-proofing
2. Information Gathering
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Information Gathering
What information is important?
• Order Completions
• Material Consumption
• Runtime and Downtime
• Good and Scrap Production
• Production Rate
• Data “Dimensions”:
•Machine
•Shift
•Operator
•Order
•Material
•Profile
•Punching
•Coil
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Information Gathering
Productivity Information Used to:
• Manage Operations Staff
• Make Capital Spending Decisions
• Direct Maintenance Efforts
• Improve Scheduling
• Evaluate Vendor Performance
• Support Continuous Improvement
Management Buy-in is Critical!
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Information Gathering OEE – Overall Equipment Effectiveness
Scrap Good Footage
Total Footage Yie
ld %
Speed Loss
Actual Speed
Max Speed Sp
eed
%
Unscheduled Downtime Running Time
Scheduled Down Time
Available Production Time
Av
aila
bility
%
Total Time
Actual Production Unrealized Capacity
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Information Gathering
Best Practices to View & Analyze Data:
• Drill-Down Reports from Summarized to Detailed
• OEE Charting Over Time
• Pareto Analysis
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Benefits of Integrated Manufacturing
1. Mistake-proofing
2. Information Gathering
3. Increased Capacity
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Increased Capacity
• Metal Buildings Industry - Runtime Percentages between 20-30%
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Increased Capacity
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7 Hrs (420 min) x 20% Runtime = 84 min 84 min x 225 fpm = 18,900 ft
25% Runtime Increase = 21 min 105 min x 225 fpm = 23,625 ft
20 sec per 10 keystrokes (500 keystrokes/shift) = 1000 sec 1000 sec / 60 sec = 17 min
Downloading Orders = Potential 20% Runtime Increase
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Financial Impact of Capacity Increases
7 hrs/day, 240 Working Days = 1680 hrs
225 fpm Throughput Rate
2% Scrap
$1.00/ft Material Cost, $1.60/ft Net Selling Price
$15/hr Total Labor Cost (fixed regardless of output)
20% Availability
95% Speed
98% Yield
OEE = .20 x .95 x .98 = 18.62%
Output = 1680 hrs x 225 fpm x 60 mph x 18.62% = 4.2 Million Feet of Good Product
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Financial Impact of Capacity Increases
Before Improvement:
OEE = 18.62%
Output = 4.2 Million Feet
After Improvement:
OEE = 23.28%
Output = 5.3 Million Feet
25% Improvement via Availability = 21 min/shift
≈ 2 mins/coil change
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After 20% OEE Improvement:
Output Increase = 1.1 M Feet
Incremental Profit = $660K
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Benefits of Integrated Manufacturing
1. Mistake-proofing
2. Information Gathering
3. Increased Capacity
4. Flexibility
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Flexibility
Low-Cost Customization
• Centralized Part Libraries
– Punching Patterns
– Trim Profiles
• Bundling
– Tickets Printed Based on Actual Production
• Marking
– Print Messages that Change Per Part
Dynamic Scheduling
• Push or pull
• Easy, On-The-Fly Adjustments
• Anticipate Problems While Time Exists to Make Corrections
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Benefits of Integrated Manufacturing
1. Mistake-proofing
2. Information Gathering
3. Increased Capacity
4. Flexibility
5. Policy Enforcement
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Policy Enforcement
• Procedures Set by Software and Machine Events
– Automatic Prompts for Data
– Sequence of Events Enforced by Software
• Inventory Management
– Material-to-Job Validation Based on Coil Number
– Tight Control and Auditing Reduces Theft
• Quality Audits
– User-defined Audits Triggered by Time, Runtime, Coil Changes, Part Count, etc.
– Machine Shutdown if Not Completed
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Scope of CIM for Roll Forming Production:
• Download Production
• Upload Completions
• Manage Part Specifications
• Track Coil Usage
• Enforce Material Selection
• Record Scrap Generation
• Record Downtime
• Track Machine & Operator Performance
• Coordinate Related Equipment
– Machine Setup
– Part and Bundle Printing
– Packaging Equipment
– Barcode Data Entry
– Preventative Maintenance
– PLC Communication
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Summary
• Direct Benefits
– Fewer Mistakes, Higher Output, Greater Flexibility
• Indirect Benefits
– Use Data to Direct Cap Ex & Management Focus
• Competitiveness
– Customer Retention
– Expanded Capacity and Faster Turn Around to Attract New Customers
• Slow Times are Ideal to Implement Integration
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AMS and CIM
• Over 20 Years Experience Integrating Roll Forming Operations
• XL200 Series Controller for Roll Forming Machines
• Pathfinder Controller for Folding Machines
• Eclipse Production Management System