Case Studies Real-time, Automated Data Empowering the Precision Machining Industry

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	Real-time, Automated Data Empowering the Precision Machining Industry

Real-time, Automated Data Empowering the Precision Machining Industry

Technology Category	Analytics & Modeling - Real Time Analytics Application Infrastructure & Middleware - Data Exchange & Integration Functional Applications - Manufacturing Execution Systems (MES)
Applicable Functions	Process Manufacturing Quality Assurance
Use Cases	Machine Condition Monitoring Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration
Challenge	A senior quality engineer for a leading machining company faced alarming scrap levels, with only hindsight data available to prevent it. Precision was crucial for the intricate manufactured components. The company had five work zones with a first-pass yield of only 40 percent, generating staggering annual scrap costs. Pertinent inspection data was manually collected and recorded, making it costly and difficult to manage. Weeks often passed before usable data became available, allowing defective products to pass through manufacturing processes with hidden issues. Identifying underlying issues required extensive efforts from Six Sigma Black Belts, often long after the fact. Read More
About Customer	Hertzler Systems has been providing seamless, accurate data acquisition solutions for over 30 years. They serve a large and diverse customer base in service, transactional, and manufacturing environments, including companies like Consolidated Biscuit Company, Darden Restaurants, Pactiv Inc., McCormick & Company, and Hormel Foods. Customers invest in Hertzler Systems' software and services to easily acquire data in any process, analyze it in real-time, and instantly notify process owners of process variations. These capabilities help clients reduce costs, cycle time, errors, and defects, while increasing profitability and customer satisfaction. Read More
Solution	The quality engineer envisioned an automated data collection system that would seamlessly integrate with the company’s ERP system, gages, and coordinate measuring machines (CMM). Hertzler Systems provided the GainSeeker automated real-time data collection system, which collects data directly from all plant devices, including the scheduling system. This system was designed to be easy for machine operators to use, enabling them to take initial actions toward problem prevention. GainSeeker empowered operators to drill down into the data in real-time to see how a process was performing, significantly improving the company's operational efficiency. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Real Time Analytics

Application Infrastructure & Middleware - Data Exchange & Integration

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Functions

Process Manufacturing

Quality Assurance

Use Cases

Machine Condition Monitoring

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Challenge

A senior quality engineer for a leading machining company faced alarming scrap levels, with only hindsight data available to prevent it. Precision was crucial for the intricate manufactured components. The company had five work zones with a first-pass yield of only 40 percent, generating staggering annual scrap costs. Pertinent inspection data was manually collected and recorded, making it costly and difficult to manage. Weeks often passed before usable data became available, allowing defective products to pass through manufacturing processes with hidden issues. Identifying underlying issues required extensive efforts from Six Sigma Black Belts, often long after the fact.

About Customer

Hertzler Systems has been providing seamless, accurate data acquisition solutions for over 30 years. They serve a large and diverse customer base in service, transactional, and manufacturing environments, including companies like Consolidated Biscuit Company, Darden Restaurants, Pactiv Inc., McCormick & Company, and Hormel Foods. Customers invest in Hertzler Systems' software and services to easily acquire data in any process, analyze it in real-time, and instantly notify process owners of process variations. These capabilities help clients reduce costs, cycle time, errors, and defects, while increasing profitability and customer satisfaction.

Solution

The quality engineer envisioned an automated data collection system that would seamlessly integrate with the company’s ERP system, gages, and coordinate measuring machines (CMM). Hertzler Systems provided the GainSeeker automated real-time data collection system, which collects data directly from all plant devices, including the scheduling system. This system was designed to be easy for machine operators to use, enabling them to take initial actions toward problem prevention. GainSeeker empowered operators to drill down into the data in real-time to see how a process was performing, significantly improving the company's operational efficiency.

Impact #1	First-pass yield increased from 40 percent to nearly 99 percent within six months.
Impact #2	Scrap costs significantly reduced for the previously problematic work zones.
Impact #3	Operators were empowered to drill down into real-time data to monitor process performance.

Impact #1

First-pass yield increased from 40 percent to nearly 99 percent within six months.

Impact #2

Scrap costs significantly reduced for the previously problematic work zones.

Impact #3

Operators were empowered to drill down into real-time data to monitor process performance.

Benefit #1	First-pass yield increased from 40% to nearly 99% within six months.

Benefit #1

First-pass yield increased from 40% to nearly 99% within six months.

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Overview

Real-time, Automated Data Empowering the Precision Machining Industry

Operational Impact

Quantitative Benefit