After an inconclusive project, how Infasco exceeded its performance target: 94.2% vs the 84% goal
- Average bolt-maker performance up from 79.8% to 94.2% (August 2023), exceeding the initial 84% target
- Mean Time To Repair (MTTR) cut by 33%, from 260 to 175 minutes
- 53 machines connected in 12 weeks, across an 800,000 sq. ft. plant
- Real-time visibility across every department and into the true causes of downtime
The Results
Note: "performance" here refers to the Performance component of OEE (Overall Equipment Effectiveness), not to be confused with overall OEE.
Project Snapshot
The Operational Challenge
Infasco had to make a vast 800,000 sq. ft. plant profitable, with bolt makers scattered across the entire floor. Without real-time visibility into machine status, the company could not know when or why production stopped: it was losing capacity without being able to explain it. After a first inconclusive project with a third-party provider, it needed a reliable partner, able to deliver on time and on budget.
The Bottleneck
Infasco's bolt makers are spread across a huge area. Management lacked reliable real-time data to know when and why machines stopped, and to tell the true causes of downtime from the irritants perceived by operators. This lack of visibility slowed every decision. The consequence: prolonged downtime and average performance stuck below 80%.
Bring average bolt-maker performance to 84% with a precise OEE analysis tool. After a first inconclusive project, the next choice had to guarantee a real reduction in manufacturing downtime.
The Deployed Solution
The OEE solution, Intelligence Industrielle's machine connectivity and productivity analysis solution, was deployed on 53 machines spread across the plant's 800,000 sq. ft. The team gained real-time visibility across every department, enough to tell the true causes of downtime from the irritants perceived by operators and to drive the performance increase.
Implementation and Adoption
53 machines connected in exactly 12 weeksThe OEE rollout was done in small batches of about 7 machines per week, over 12 weeks. This progressive method made adoption easier for employees. To motivate operators, a performance leaderboard was set up on the floor.
- 1Rollout in small batches of about 7 machines per week
- 2Performance leaderboard on the floor to motivate operators
- 353 machines connected in exactly 12 weeks
Adding an "End of repair" button on the tablets sent an automatic SMS to the supervisor. This instant communication got machines restarted much faster, drastically reducing repair time.
"The solution's flexibility and self-configuration capability are particularly appreciated."
David JeannotteProduction Director, InfascoHandling Objections
Reliability after a bad experience
Following an inconclusive project with a third-party provider, Infasco demanded a serious and reliable partner. Intelligence Industrielle's approach proved it is possible to deliver on time and on budget.
Meeting implementation deadlines
The client feared IT projects that drag on. The batch approach connected 53 machines in exactly 12 weeks.
Guarantee of tangible results
Infasco refused empty promises. The first productivity gains were quantified and demonstrated within the first quarter of use.
