Automated Stamping • Automated Intelligence
 
 
Some Common Stamping Process Issues Resolved By Using BirdsEye

There are essentially three major issues that continuously plague stamping operations: machine down-time, increased cycle times, and part quality variation. All of these issues directly translate to a loss of production and increased cost per part. It is difficult to assess the various causes of these issues without an advanced analytics system coupled with proper education and training. It is also difficult to properly integrate an analytics system without interfering with the current manufacturing process. BirdsEye does this without interference.

Problem Benefit of Solution BirdsEye Feature
Installed PLC I/O Forces
  • Bypass lube low
  • Bypass air pressure low
  • Bypass dirty filter
  • etc.
Reduce downtime due to machine damage because of undocumented or forgotten PLC FORCE usage. Automatically track and alert to possible short-term and/or long-term process issues with:
  • BirdsEye OVERVIEW
  • BirdsEye FORCE
  • BirdsEye ALERT
Modified PLC logic
  • Process control code change
Reduce downtime due to unverified or undocumented PLC logic change(s). Visually shows modification history on Production Scope with:
  • BirdsEye OVERVIEW
  • BirdsEye ENGINEER TOOLKIT
Machine operator critical recipe parameter modifications
  • Shut-height
  • Press speed
  • Gauge positions
  • Counter-Balance air pressure
  • Cushion air pressure
  • etc.
Reduce negative production impact by making corrections quickly:
  • Reduce downtime due to part misgauge, etc.
  • Improve cycle rate by eliminating unnecessary slowdowns
  • Maintain quality by verifying all recipe parameters within tolerance
Keeps all necessary personnel on top of process variable changes with:
  • BirdsEye OVERVIEW
  • BirdsEye RECIPE
  • BirdsEye ALERT
  • BirdsEye MOBILE
Excessive production schedule variation
  • Late production starts
  • Early production stops
Improve and sustain line start/stop promptness by viewing daily production start and stop times. Keeps all departments accountable to plant scheduling with:
  • BirdsEye OVERVIEW
  • BirdsEye WEB
  • BirdsEye MOBILE
  • BirdsEye ALERT
Poor cross-plant, cross-shift communications Improve cross-plant/cross-shift communications by automatically collecting and providing access to downtime details that can be used by other personnel on other shifts or other parts of the plant. Keeps permanent unbiased records for a better sense of awareness with:
  • BirdsEye OVERVIEW
  • BirdsEye DOWNTIME
Weekend labor due to lower than planned production volume Reduce unexpected overtime by keeping an attuned eye on all production systems behavior. Fix problems (even the smaller nagging ones) sooner than later. Keep all plant personnel aware of process critical conditions with:
  • BirdsEye OVERVIEW
  • BirdsEye WEB
  • BirdsEye MOBILE
  • BirdsEye ALERT
Process flow issue due to FOL (Front‑of‑Line) Starved
  • Line waiting for new blanks or coil
Reduce line "starved" time by being made aware of this circumstance as soon as possible; drive an alert, or call a forklift with specific material requests. Keep everyone aware of current material needs with:
  • BirdsEye OVERVIEW
  • BirdsEye WEB
  • BirdsEye MOBILE
  • BirdsEye ALERT
  • BirdsEye PROGRAMMER TOOLKIT
Process flow issue due to EOL (End‑of‑Line) Blocked
  • All racks/bins full
  • No racks/bins to load
  • All personnel busy
Reduce line "blocked" time by being made aware of this circumstance as soon as possible; drive an alert when racks/bins are 95% full. Keeps everyone aware of material storage needs with:
  • BirdsEye OVERVIEW
  • BirdsEye WEB
  • BirdsEye MOBILE
  • BirdsEye ALERT
  • BirdsEye PROGRAMMER TOOLKIT
Material shrinkage Automatically measure parts in and parts out to ensure proper material accounting and vendor accountability. Detailed raw inventory control can be monitored in real-time and automatically analyzed with:
  • BirdsEye PROGRAMMER TOOLKIT
  • BirdsEye ENGINEER TOOLKIT
Losing hard earned ADC gains Ensure ADC times remain consistent by statistical real-time analysis and ADC start alerts and ADC long alerts. Never let an ADC anomaly turn into the norm by alerting and analysis with:
  • BirdsEye ALERT
  • BirdsEye PROGRAMMER TOOLKIT
Losing hard earned production gains Eliminate production losses due to operator decision by immediately knowing that the output of the line has been reduced (or increased). Keep an eye on part production trends to ensure consistency into the future with:
  • BirdsEye OVERVIEW
  • BirdsEye WEB
  • BirdsEye MOBILE
  • BirdsEye PROGRAMMER TOOLKIT
Fault recovery bottle-necks Reduce recovery times by analyzing and modifying machine operations and/or personnel behaviors (training). Easily justify system upgrades and/or operator training with:
  • BirdsEye PROGRAMMER TOOLKIT
  • BirdsEye ENGINEER TOOLKIT
  • BirdsEye ALERT
Multi-shift output variation Reduce operator negative production impact from shift-to-shift by watching for unnecessary process variable changes. Quickly audit shift-to-shift production statistics to confirm production rate stability with:
  • BirdsEye OVERVIEW
  • BirdsEye WEB
  • BirdsEye MOBILE
Over/Under preventative maintenance Decrease machine downtime by setting aside PM's for machinery that requires it only. Monitor system usage and statistically determine the proper PM frequency with:
  • BirdsEye PROGRAMMER TOOLKIT
  • BirdsEye ENGINEER TOOLKIT
Unaccounted for production time losses Use 24/7 monitoring to automatically catalog all production and production-loss activity to ensure repeat issues are minimized Automatically track weekly statistics to ensure machine fixes or upgrades are still in place with:
  • BirdsEye PROGRAMMER TOOLKIT
  • BirdsEye ENGINEER TOOLKIT
Unaccounted for low production rates Use 24/7 monitoring to automatically identify all production rate decreases to ensure repeat issues are minimized Never let a bad setting cost you, stay aware with:
  • BirdsEye RECIPE
  • BirdsEye PROGRAMMER TOOLKIT
  • BirdsEye ENGINEER TOOLKIT
Make one phone call to take another positive step towards greater profitability and continuous improvement.

How can the InVanse® BirdsEye Automated Process Control System transform your operations?

Call us at 248.275.1125 today to learn more ... or click here to request more information.
© 2009-2018 InVanse Technologies, LLC
330 East Maple Road, Suite B, Troy, Michigan 48083 • Phone: 248.275.1125 • Fax: 248.928.0939

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