Hi-Tech Manufacturer Realizes Continuous Improvement with the Sepasoft OEE Downtime Module!
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Manual Data Collection Gets an Upgrade
Prior to implementing the Sepasoft™ OEE Downtime Module as a solution, continuous improvement was entirely dependent on manual data collection and user input. Data collection was therefore unreliable and askew, hidden from the process engineers and the manufacturing floor.
“It [data collection project] quickly turned into using the MES modules from Sepasoft™ due to the easy integration with the Ignition® platform.”
―Oscar Salcedo, Global Systems Integration Manager
Built on the Ignition® platform, the Sepasoft™ OEE Downtime Module helps Samtec maximize efficiency thereby transforming their entire manufacturing data process, from a time consuming manual effort to a more robust automated process. Samtec needs constant visibility of process variables in real-time, as well as monitoring for key quality and process indicators like chemical compositions, temperature, and line or plating speeds. Samtec was able to harness their raw data in context, using it to drive continuous improvement, resulting in a more efficient production environment with remarkable cost savings.
One key element Samtec capitalized on was tracking the consumption rate of gold during their plating process. The Sepasoft™ OEE Downtime Module helped eliminate waste and ultimately realized a substantial cost savings benefit solely from managing their gold plating process. Furthermore, efficiency made significant gains for Samtec due to their ability to monitor their production in realtime, a big upgrade from their prior monthly manual tracking process.
“Our gold saving numbers have been our biggest financial benefit from this, raw materials are a big cost for us. We plate with gold, so being able to monitor in real-time our consumption rate of gold has been big for us. Where we used to wait until the end of the month and balance our gold numbers, now we can see that on a daily basis by line, by part number, and by operator. So we can quickly identify areas where we are using too much gold.”
―Jeff Matheny, Global Technical Manager
Reliable Integration to Implement a Robust OEE Solution
To ensure reliable integration, Samtec initiated the project with a systems integrator. Following that initial phase, internal engineers who had completed hands-on training and received design consultation support filled out their tailored solution. Sepasoft™ guided Samtec every step of the way to ensure their solution was ready to hit the ground running.
Since completing implementation a handful of years ago, Sepasoft™ continues to provide Samtec with Design Consultation and Tech Support solutions as needed. Support is simply a phone call away, no long wait times, no pre-recorded messages, and after hours availability for those issues that simply cannot wait.
“Certified Integrators came in and helped us; we implemented one machine first and we started with that machine, got it as solid as we could, and we built it in a way that could be scaled out to multiple machines.”―Jordan Rajchel, Systems Integration Engineer
Customizing our MES Modules to Fit Samtec’s Business Structure
One of the ultimate successes realized during this OEE implementation was the dexterity and flexibility to customize the MES software to accommodate Samtec’s business needs. Sepasoft™ takes pride in their ability to provide a basis for customization regardless of what the current landscape may be. By offering features, such as custom scripting, Samtec can capitalize on flexibility to add to an existing manufacturing process and help enhance the production environment moving forward.
Samtec already had their manufacturing systems in place, machines in operation, and people trained to utilize their current structure. By introducing Ignition® and the Sepasoft™ OEE Downtime Module featureset, they were able to connect, enhance, and provide deep value for continuous improvement.
“We have the ability to pretty much integrate with any system that we have already built and to build alongside those things…like our Auto-Tech Dashboard, that’s completely based on data from one of our Samtec-built systems, but it shows [data] in a different way that it never had before.”―Jordan Rajchel, Systems Integration Engineer
“Samtec picked Ignition® and Sepasoft™ because of their flexibility and their ability to quickly connect to machines and to get us the real-time data very quickly to be able to throw up dashboards and all these things very rapidly.”
―Jordan Rajchel, Systems Integration Engineer