94.2%
average bolt-maker performance in August 2023, up from 79.8%
Target: 84%
Success Story: Infasco
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
By the numbers
The Results
-33%
on Mean Time To Repair (MTTR), down from 260 to 175 minutes
53
machines connected in 12 weeks, across an 800,000 sq. ft. plant
Note: "performance" here refers to the Performance component of OEE (Overall Equipment Effectiveness), not to be confused with overall OEE.
"The solution's flexibility and self-configuration capability are particularly appreciated."
The client
Project Snapshot
- Company
- Infasco, manufacturer of threaded fasteners and forged parts based in Marieville, over 400 employees, a member of the Heico group since 1960.
- Solution
- The OEE solution, Intelligence Industrielle's machine connectivity and productivity analysis solution, deployed on 53 machines.
- Value
- Bolt-maker performance raised from 79.8% to 94.2%, MTTR cut by 33%, and real-time visibility across 53 machines.
The context
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.
On the floor
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%.
79.8%average bolt-maker performance, before the project
The objective
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.
Your plant
Contact usSee how to gain visibility into your downtime
TRG solution
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.
- 01
OEE solution deployed on 53 machines in 12 weeks
- 02
Real-time visibility across every department
- 03
The true causes of downtime identified
The rollout
Implementation and Adoption
The 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.
- 01
Rollout in small batches of about 7 machines per week
- 02
Performance leaderboard on the floor to motivate operators
- 03
53 machines connected in exactly 12 weeks
- 04
First significant results visible after about one quarter
The trick that changed the game
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.
Common questions
Handling Objections
Reliability after a bad experience
Meeting implementation deadlines
Guarantee of tangible results
Customer stories
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