Automotive Glass Maker Gains a Clear View of Production and Reduces Scrap 30 Percent with Manufacturing Intelligence

A Solution by Stages

The glass manufacturer decided to get rid of the homegrown solution, and designed a manufacturing intelligence system that would be deployed over three years in two stages. The system would collect information across the process and discrete areas of production.

The system design heavily focused on manufacturing software solutions from Rockwell Automation. According to the company’s project lead and engineering manager, the decision came down to the support availability and the off-the-shelf nature of the offerings.

“Developing custom code would only put us back on the path to a homegrown solution,” the project lead said. “We selected a manufacturing intelligence solution from Rockwell Automation that would allow us to customize a standardized solution across lines, and provide us access to a Rockwell Automation field engineer for help on-site when needed.”

The first stage: data-collection and analytics requirements. The team deployed FactoryTalk^® Metrics software from Rockwell Automation on more than 20 work cells per line. Engineers use the software to generate real-time data reports on OEE, production counts and yield counts. Coupled with FactoryTalk View HMI software, engineers can see this information via any plant HMI or via a web browser from their desktop, laptop or mobile device.

In the second stage, the project team implemented FactoryTalk VantagePoint^® software from Rockwell Automation to produce reports specific to individual production areas, so each work shift could make changes to reduce scrap and improve productivity. They also set up a self-service station for plant-floor staff to access the scalable reporting tool.

Engineers – even those relatively new to the position – can easily walk up to the station on the plant floor and choose the desired data set and time range. They can pull two-hour reports specific to their production area and the responsibilities associated with their role. With these insights, control and process engineers can dig into data behind any production issues to identify bottlenecks and root causes. Management can access real-time and trending production totals, enabling them to make production changes as customer orders arrive.

The team also employed a notification functionality in the software. They can now send emails and texts with production information to plant-floor staff on-site and off-site. This helps further reduce downtime and mean time to repair.

Rapidly Reducing Scrap

The FactoryTalk VantagePoint self-service station has reduced requests for data pulls from project leads by 90 percent. The team works directly with each other and more easily collaborates to optimize operations, reducing downtime section by section.

The upgraded facility is helping the glass manufacturer meet customer orders, allowing the company to continue growing. In addition, the system’s insights are enabling future improvements at the facility. The team is aiming for a further 30 percent reduction in scrap by the end of the year.

The team is also considering expanding the system to include energy-management reporting and FactoryTalk AssetCentre software from Rockwell Automation. This will provide access to critical energy information and better manage asset information from a central database.

The results mentioned above are specific to this company’s use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.

FactoryTalk and VantagePoint are trademarks of Rockwell Automation Inc.