Managing Automation - September 2007 - (Page 45)

because Mar tinrea deployed technology that helps the business and executed the project within the confines of a highspeed production environment that leaves little room for error. “I liked the Martinrea program because they face the same type of issues Rexam faces in a highspeed production environment where downtime is not an option,” he says. “It is difficult to raise OEE, but to use IT to increase OEE and productivity by 50% is outstanding. That impacts the bottom-line profitability.” One reason Martinrea chose Rockwell is that it offered support on top of the technology. “We have a small shop as far as IT goes,” Allison says, noting that at the time of the deployment, he was the only person managing the data collection process for 50 to 100 machines. “We wanted a self-sufficient system that, once in place, did not require a lot of hands-on from IT.” Rockwell’s FactoryMetrics software was installed to collect the OEE data, including production counts and event-based reporting. And a Web-based reporting system built on Microsoft SQL Server translates to the corporate side of the business. “Ninety percent of users utilizing the system are office personnel and management who are used to the Microsoft world,” Allison says. The SQL Server engine pulls information from FactoryTalk Metrics and uses the SQL Server Reporting Services to report the data “so users can be in that Microsoft comfort zone.” The technology is tied tightly to Martinrea’s Six Sigma methodology, Allison says, enabling engineers to resolve problems more quickly by giving them immediate access to historical data about each machine. “If a customer request comes in to increase production by 50%, we are able to look at the machinery and determine if it is feasible,” Allison explains. By bringing the machines up to their highest efficiency, operators don’t have to work overtime. As work flexibility and workflow increase, Martinrea can start to think about the next step. At the Hopkinsville facility, where volume averages from 10,000 to 13,000 parts per day, Martinrea is evaluating Rockwell’s Production Centre MES product, which will add shop floor genealogy and product traceability, from raw materials to finished goods. The technology was the easy part of the Managers have to project, Allison says. The more difficult part “agree that data is a was getting buy-in from managers who have to value-add that, when “agree that data is a value-add that, when utiutilized to make busilized to make business decisions, will improve ness decisions, will processes,” he says. For success, at least 85% improve processes,” of the management must be on board. says Darren Allison, IT Once Allison got the go-ahead he needed manager at Martinrea. from upper management, he was unprepared for the culture clash that ensued between the engineering and IT groups. To offset the potential problems associated with territorial ownership, Allison created common ground by building a converged IT/engineering group working specifically on the shop floor. It’s a matter of defining roles and ensuring that everyone understands their job, he says. But the biggest takeaway from this project is to think outside the box. “Never underestimate the flexibility of a system just because of what a sales brochure shows you,” Allison says. Martinrea pushed the FactoryTalk Metrics application beyond what people managingautomation.com expected it to do. “The perception is that it does OEE data collection, but RELATED ARTICLES: we collected everything from repairs MDM Ingrained in Plant Floor to operator log-on.” Information Systems www.managingautomation.com/integration22 But that is not as easy as it sounds. “To standardize reporting, provide Pumping Up Data Historians www.managingautomation.com/data a real-time common view into the plant floor operations, and manage MES Turns Sweet 16 www.managingautomation.com/edges15 11.5 million transactions per day is not easy,” Rexam’s Martin says. ■ maonline Photo: Harrison McClary/ReduxPlus September 2007 45 http://managingautomation.com http://www.managingautomation.com/integration22 http://www.managingautomation.com/data http://www.managingautomation.com/edges15

Table of Contents Feed for the Digital Edition of Managing Automation - September 2007

Contents Take 1 Europe’s Automation Chiefs Upbeat on ’08 Business Prospects Vendor Coalition Pushes Human Element of SOA Wireless: Users Still Approaching with Caution One Year Later, IBM Shows Plan for MRO’s Maximo Study: More Work Needed to Lure Next-Gen Talent Executive Q&A Notes Cover Story: 2008 Companies to Watch Special Report: The 2007 Progressive Manufacturing High Achievers Progressive Manufacturer of the Year Business Model Mastery Innovation Mastery Customer Mastery Supply Network Mastery Data & Integration Mastery Education & Training Mastery Operational Excellence Mastery Leadership Mastery Transformation: Orchestrating the Multi-Tier Supply Network Integration: The Timeless Quest for Accurate Data Industries: Maintenance No Longer on Schedule Product Scan Advertiser Index Next

Managing Automation - September 2007

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