Using Big Data To Track Your Parts

When it comes to capturing big data to track and market your future business, Konnection software allows you to use a variety of collected data from your plant floor to make decisions for your business. Imagine being able to use PLC, equipment, process and ERP/MRP data to see past trends and analyze root cause and energy use over your entire process.

Production data is key to making sure your system is efficient and profitable. Konnection software turns your data into easy to read graphs detailing the information you have in a reviewable database created by your real-time production. This allows you to monitor production like never before. Recognize trends, view your total number of jobs and carriers, maximize shift productivity and track unproductive aspects of your floor.

Process tracking allows your company to ensure quality of your work and provides your operators detailed work instructions, the ability to compare shift reports and closely monitor energy and resource usage. Ensure that your parts went through the finishing system in the same amount of time every time. Use our software to check coating times, or when carriers entered and exited the system. With this information you can answer questions about what’s happening at every point in your process. With Konnection software, you’ll know everything about the process — even down to if your operator held or released the carrier within the allotted time.

systemreport

Production data is key to making sure your system is efficient and profitable. Konnection software turns your data into easy to read graphs detailing the information you have in a reviewable database created by your real-time production.

Tracking your parts is essential to making sure you are getting the most out of your process, and ultimately your business. With this level of system reporting, you can easily locate parts in the finishing system, and have their data accessible at a later date via serial numbers. An overview screen gives a visual representation of your stations and are color coded for quick detection for status review. You can see what is loaded on each carrier, where that carrier is in your system and then quickly export the selected data via spreadsheets or .csv files. Data can also be filtered by any field, allowing you to look at the production of a single part over a month or at all parts produced in a day.

Our Konnection software connects to your factory floor to your upper level software like SAP and your ERP seamlessly with the format of the data translated to read E-Net, DeviceNet, ProfiBus, ModBus, Serial and many more. The core of our software is SQL server that utilizes redundant servers, and is capable of using your existing hardware. This web-based software is visible from mobile devices and can even send text messages and alarms fault to the screens.

For more information on how you can maximize your plant floor, contact IntelliFinishing with your request for Konnection software.

Lean seminar hosted by IntelliFinishing is educational

Garyfrom TCA

Gary Conner from TCA

Lean was the focus of the Midwest Coatings Seminar on August 8th in Salina, Kansas. Gary Conner from Technical Change Associates shared many valuable stories from his experience implementing lean for his own company, as well as leading companies on their lean journey. Brad Muir, president of Technical Change Associates continued the discussion reviewing a variety of plant layouts.

The group of approximately fifty attendees from regional manufacturers learned that the implementation of lean is more than using the lean tools. Working with the diverse personalities of a team and listening to their concerns will help ensure a successful outcome and build a culture of continual improvement.

Brad shared before and after’s of plant floor layouts. One case study from a few years ago presented an impossible challenge for the manufacturer due to constraints on the finishing line. At the time, Brad concluded that the layout he desired was impossible because of the limitations of the conveyors. Upon learning more about IntelliFinishing, Brad and the IntelliFinishing team designed a couple of different layouts that would have worked for the manufacturer.

Dan Stutterheim, CEO of Kasa Companies followed up with a presentation on Eliminating Waste from Communication. David Underhill, IntelliFinishing Sales provided a presentation on Improving Production Line Gaps.

 

 

Learn about Lean at Midwest Coatings Seminar 2013

MCS-thumbnailAre you new to the industrial coatings industry, or want to learn more about Lean Manufacturing and how it can be applied to your manufacturing process? Join us at the third annual Midwest Coatings Seminar on August 8th to network with other manufacturers and suppliers in the area, learn about how to implement lean, and see a live demonstration of IntelliFinishing’s new spinning tube conveyor technology.

This year’s presenters include Brad Muir and Gary Conner of Technical Change Associates who will be discussing Lean as a growth strategy. Experts in the field with over 40 years of experience, Brad and Gary will cover the tools and techniques to successfully implement lean into your manufacturing and finishing processes.

Following this interactive presentation, you will have two options.

Option 2 – Improve Production Line Gaps, presented by David Underhill of IntelliFinishing. Learn how production line gaps can be improved or eliminated with the right conveyor and controls. David has over 30 years of experience in the finishing and conveyor industry and will touch on topics of inventory problems, reduced production throughput, and other negative effects of production line gaps.

Option 1 - Improve Communication by Removing Waste presented by Dan Stutterheim, CEO of Kasa Companies: Lean.  In manufacturing, it means reducing waste, specifying value from your customer’s perspective, and allowing it to flow.  Can you apply these Lean Principles to the way your organization communicates? Absolutely. Long emails will be reduced to sentences.  You can communicate your vision, your plan, and your instructions in a way that everyone understands the message and acts upon it appropriately.  Reducing waste in communication is based upon learning the six personality types and a new concept of communicating called the Process Communication Model (PCM)®.  Applying these concepts will lead toward a trusting and efficient workplace where everybody understands the intent of your message and acts upon it appropriately.

If you are able to stick around for dinner, IntelliFinishing will host a BBQ at their main facility just a few blocks from the seminar. The informal dinner is a great opportunity to visit with other attendees or ask the presenters in depth questions relating to your specific situation.

To learn more, register for the event, or view the schedule, point your browser to www.leanfinishing.com.

Part IV: Detailed Recipes Make More than Grandma’s Brownies

picture of brownies

Grandma’s brownies

Going beyond our technologically advanced components and space saving design, a large part of our job at IntelliFinishing is working with our customers to solve their problems and challenges. There are usually a few key hurdles that lead a customer to consider purchasing a system or renovating their existing setup. As part of a four part series, we will look at the specific challenges one of our recent customers faced, and the solutions provided by IntelliFinishing.

The final major challenge presented to us by our customer was the desire to integrate technology and traceability into the new paint system. The parts being produced at their facility often ended up in military applications, so the more data they could track, the tighter their process controls – and thus quality – could be.

IntelliFinishing’s solution was to introduce our Enterprise Automation Software technology which provides detailed part tracking, parameter monitoring, and full system traceability. Using this system meant that every part was set up with a recipe to define paint spec, masking instructions, curing time, and all other information tied to that specific product. Products can be grouped so items that follow similar processes can be put together.

In operation, parts are scanned with a barcode reader when racked on a carrier, instead of hand-writing a job traveler. Once the parts are scanned onto a loadbar, interactive touch screens at the load station can notify the operator of incompatible part families and diagrams of how to hang or mask the part. As the loaded carrier moves through the system, the touchscreens can show the status of each carrier, such as how long it has been in the oven. This information can also be accessed from a secure desktop log-in elsewhere in the plant. For this customer we were able to provide product logging that showed items like time and date stamps for when the product was painted, who the operator was, the temperature and humidity of the curing chamber. These and all other information is tracked and logged in a secure server so if a quality issue arises it can be traced back to the source of the problem.

The beauty of IntelliFinishing’s Enterprise Automation Software is that it is virtually limitless in the data and information it can track, log, and show. Passwords and user ID’s can also be set up to restrict editing capabilities, etc. The system can also be used for labor tracking and efficiency studies.

Call us today and let us show you how we can track your success!

Part III: The Lights are On, But No One is Home

Going beyond our technologically advanced components and space saving design, a large part of our job at IntelliFinishing is working with our customers to solve their problems and challenges. There are usually a few key hurdles that lead a customer to consider purchasing a system or renovating their existing setup. As part of a four part series, we will look at the specific challenges one of our recent customers faced, and the solutions provided by IntelliFinishing.

The third goal for our customer was to reduce energy consumption and eliminate waste as much as possible. This makes sense, as energy rates continue to rise and the emphasis on lean and green continues to grow.

As we promote so often at IntelliFinishing, independent studies have shown that our unique chainless power and free conveyor can save over 40% on utility bills when compared to the antiquated monument systems. This held true for this project as well, but there were other innovations that helped as well.

Simply replacing the 6 open-faced paint booths with a single automated booth went a long way in reducing energy use on the booths themselves, as well as the air handling units used to condition air going into and air being exhausted from the paint line. Our conveyor line is also decoupled, allowing each drive section to operate independently, only running when a carrier is present. The same could be said for the process washer as well. So while a monument system may have two or three large motors pulling chain continuously, the IntelliFinishing system breaks our conveyor down into much smaller sections that are controlled by much smaller variable speed drives. In this way, more motors does not equate to greater electricity usage, but actually reduced demands and added great flexibility.

The process equipment used in IntelliFinishing systems is also a step above the industry norm. Our oven and washer panels are insulated to help keep chemical tanks and curing chambers at temperature. On average this makes our process equipment 75-80% more energy efficient. Automated product doors also help to prevent heat loss. As a side note, the insulated ovens we incorporate in our systems also prevent accidental burns of employees. Even running at temperature, you can place your hand on the sidewall.

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