See the value that AeroScout WIP throughput solutions have brought to our industrial customers; increase scheduling accuracy, improve efficiency, and streamline production.
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WIP Throughput customer stories from Extronics Advance
1. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
WIP
THROUGHPUT
CUSTOMER STORIES
1.
2. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
WIP THROUGHPUT CUSTOMERS
Viracon
Continental Tire
Boeing
John Deere
Freescale Semiconductor
Caterpillar
Wrigley
Komatsu
Celanese
Daimler
2.
3. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Continental, the leading global tire manufacturer
Where?
US and France
Why?
Long searches for assets increased cycle times, decreased
labour optimisation, and increased non-compliance. There
was also a high scrap rate.
Reduce cycle times, improve labour optimisation, and increase compliance with production
schedules by reducing search times for assets
Reduce high scrap rate, associated with lost carriers
Goals
All carriers tracked in real-time using T2-EB tags on a Cisco Wi-Fi network
Material handlers, truckers, and managers can search in real-time for components by ID,
tread number, material code, or according to date (FIFO inventory management)
MobileView is displayed on the carrier tug
Integrated with Continental’s MITS (Material Inventory Tracking System)
Automated alerts, such as empty carriers requiring collection
Reduced operator search times thanks to continuous real-time visibility across entire plant
20% reduction of breaker component tire loss
Increase in tire machine utilisation, ensuring increased production and higher overall
equipment efficiency (OEE)
Reduction in scrap loss through FIFO component management
Solution overview
Outcomes
TYRE MANUFACTURING THROUGHPUT
3.
4. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Freescale, the multinational semiconductor company with
design, research and development, manufacturing, and sales
operations in more than 75 locations across 19 countries
Where?
Texas, USA
Why?
Lengthy manual searches were inefficient and reduced
production efficiency. Customer satisfaction was also
impacted due to delayed deliveries.
Improve production throughput by increasing efficiency of labour use and reducing search
times
Increase customer satisfaction through fewer production delays, enabling delivery times to
be met
Goals
Tags were mounted on 4,000 wafer lots with exciters above the WIP tracks for rack level
accuracy
Additional exciters used throughout the fab for WIP tracking
MobileView integrated with the fab’s MES to ensure schedule compliance
Requested carrier from MES sends a signal to MobileView activating a blinking LED on the
tag
Freescale’s productivity improvement and throughput increased by 6.8%
Average lot transaction time was reduced by 82%
On-time deliveries improved by 13%
Dispatch compliance improved by 8% (photo-lithography increased by 25%)
Operator headcount could be reduced by 10%
Dwell times and lost lot events were decreased
Solution overview
Outcomes
“The payback has exceeded our
expectation, 82% improvement
in retrieval time resulted in
increased throughput, and on-
time delivery was improved by
13%”
- Chris Magnella, Operations
Manager
LOT BOX TRACKING
4.
5. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Caterpillar, the designer and manufacturer of construction
and mining equipment, engines, turbines, and locomotives
Where?
US and UK
Why?
There was a lack of visibility of Caterpillar’s Front Loader
manufacturing line, and manually locating jobs reduced the
plant’s efficiency
Give visibility into real-time production and individual department productivity
Improve plant manufacturing efficiency
Goals
T2-EB tags attached to the Loader chassis with tie wraps at the start of the production line,
staying attached until the end of the manufacturing process
EX2000 and EX3210 exciters mounted along department entry and exit points throughout
manufacturing line
MobileView displays real-time counts of Loaders in each department or stage
Established MobileView alarms to monitor Loader dwell time in the department, configured
to >40 minutes
System provides production management with continuous visibility of the Loader
manufacturing progress within each department
Track and trace at department level continuously measures real-time performance against
the daily manufacturing goals
Real-time notification is sent if daily manufacturing goals are in jeopardy due to department
dwell time
Production data is used to analyse bottlenecks to streamline process and improve efficiency
Solution overview
Outcomes
HEAVY EQUIPMENT MANUFACTURING
5.
6. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
William Wrigley Jr. Company, the food processing company
and chewing gum manufacturer with operations in over 40
nations
Where?
Multiple worldwide locations
Why?
Complex routings and product processing needed to be
simplified, and hundreds of similar pallets requiring this
complicated processing made operations less efficient
Enable quick identification of correct pallet amongst multiple similar pallets
Support simplification of processing throughout network of sophisticated, highly-regulated
facilities around the globe
Goals
Tags mounted on 400 pallets
Leveraging existing Cisco LWAPP access points deployed in factory
Exciters located at each loading and unloading station to provide immediate arrival
information
Integrated with Wrigley’s production software and provides seamless location accuracy
Temperature monitoring tags placed on each of the pallets in cooling tunnels
Wrigley experienced a reduction in the quantity of scrap material
Manufacturing processing and product quality improved
Incorrect processing is avoided
Better control of manufacturing and packaging processes
Solution overview
Outcomes
MANUFACTURING QUALITY
6.
7. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Komatsu, Japan’s largest manufacturer of construction and
mining equipment, with 45 factories
Where?
The Osaka plant in Japan, which is responsible for designing
and building all Komatsu products
Why?
Manual searches for vehicles were time-consuming and
caused delays, which harmed customer satisfaction
Improve customer satisfaction
Improve search times
Goals
T6 GPS tags placed on units at the beginning of production
Leveraging the existing Cisco Wi-Fi network, choke point exciters, and GPS satellites to
track units both indoor and outdoors
MobileView software integrated with Komatsu MES software to optimise operations
Komatsu experienced reduced lead time in 7 areas: Transport, Motion, Waiting, Over-
producing, Over-processing, and Defects
Productivity increased as they cannot reduce ‘wastes’ unless it is visualised
Fixture search times was all but eliminated
Customer satisfaction improved due to real-time data and ease of response to queries from
field
Solution overview
Outcomes
HEAVY MANUFACTURING THROUGHPUT
7.
8. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Celanese, the global technology and specialty materials
company
Where?
Mexico
Why?
The company was experiencing bottlenecks with trucks or
drivers not where they were needed
Improve port throughout
Ensure the right truck and the right driver arrived at the right location at the right time
Goals
Partner GDSI implemented a mixed solution that included both active and passive RFID
Cisco wireless network was installed throughput the plant
AeroScout technology tags were mounted on mobile, high-value assets whilst passive RFID
tags were used for low-value, less mobile assets
MobileView software used to track both active and passive tagged assets
Celanese experienced significant throughput improvement through the facility
Increase traceability of parts and components
Solution overview
Outcomes
DISTRIBUTION THROUGHPUT
8.
9. SMART, SAFE, AND CONNECTED.SMART, SAFE, AND CONNECTED.
Who?
Daimler, the German international automotive corporation
Where?
Engine remanufacturing facility in Mannheim, Germany
Why?
Engine remanufacturing progress was difficult to determine,
and covered 5 buildings on a very large site. The facility
takes special expedited orders for customer satisfaction, so
misplacing engines had a negative impact
Avoid misplacing engines during remanufacturing process by tracking engines across whole
site
Improve customer satisfaction
Goals
Tags mounted to engine carrier frames
Tags are married to a tracking system at process start, via a barcode
Steps and areas marked with zones and exciters
Engine location can be discovered via either the shop floor system or MobileView
Misplaced engines eliminated, increasing on-time deliveries and improving customer
satisfaction
Customer retention improved due to more accurate order updates
Throughput increased by eliminating unnecessary movement
Cycle times predictability and consistency dramatically improved scheduling and customer
service
Solution overview
Outcomes
ENGINE REPAIR AND OVERHAUL
9.
10. SMART, SAFE, AND CONNECTED.
Thank you.
If you would like further information,
please get in touch via info@extronics.com
or call us on +44 845 277 5000