Tait Communications, a leading Lean Practitioner in New Zealand needed further output and productivity increase. They turned their eye to the emerging technology and approaches under Industry 4.0. As one of New Zealand’s leading 4.0 experts, LMAC guided Tait towards the power of IoT and Big Data.
Tait Communications design and manufacture bespoke communications equipment. The nature of their products and build-to-order environment results in a very high product mix, low volume manufacturing system. Their SMT lines were at capacity output with un-expected demand increase looming.
We established there was an opportunity to use a Data driven approach to unlock further output on existing SMT lines. We discovered that the Data being generated by the SMT lines was under utilised and stored in disparate systems. By “cleaning” this data, connecting systems via IoT, and a series of algorithms we were able to achieve the following:
- Predictively plan job sequence whilst maintaining JIT delivery.
- Optimise total time elapsed of change-over + run time.
- Heijunka change-overs between SMT lines.
- Align machines with human activities.
Increase in volume output on the focus SMT production line.
Increase in volume output across all SMT lines.
Direct business benefit in 6 months