Case Ojala Group:
Ojala Group ended up choosing the WBS Productivity solution due to its unique features
Ojala Group is a sheet metal production forerunner specialized in contract manufacturing. To improve production efficiency and competitiveness a WBS Production solution supplied by Control Express Finland was bought to the Ojala Group´s Sievi factory. The solution is used to monitor productive machinery.
In sheet metal production and contract manufacturing production efficiency is critical. In Ojala Group´s Sievi factory production efficiency has been measured for several years. Before measurements were done manually among other things by clocking and writing the results down by hand. During the recent years the Sievi factory tested also products of other manufacturers. According to Factory Manager Jari Linnala the greatest deficiency was the incapability to receive reliable real-time information. “We want to receive up-to-date information instantly, not after a weeks’ time. It is important to receive information how a machine has been used each moment in each day”, Linnala describes his earlier experiences.
Ojala Group ended up choosing the WBS Productivity solution for the utilization rate follow-up of their production machinery. The decisive factor was the fact, that WBS Productivity does not require to be connected to separate machinery systems and the CEF´s solution is suitable as such to all machine types in the Sievi factory. “The factory has 10 to 15 machines built by different manufacturers, their age differences exceeding even 20 years”, Production engineer Harri Häggman describes. According to him with other OEE-systems this would not be possible.
Quick implementation and ease of use as competitive advantages
WBS Productivity solution consists of intelligent sensors, a data acquisition unit and a software application. In the Sievi factory of Ojala Group there are approximately twenty production cells and all of their main machines have sensors. WBS Productivity solution measures the usage efficiency in shifts and represents the information in an easy to read way for different user groups.
The measurement of production efficiency involves also changes in daily operations models. According to Factory Manager Jari Linnala changes always include uncertainty, but the personnel has received the new operations model favorably. The discussion about using production machinery utilization follow-up began before the pilot program and the follow-up was made together with the workers. The piloting and installation was made in collaboration with the machine users.
The system implementation at the Sievi factory took place gradually. The sensors were located in suitable places in the pilot phase, afterwards the comprehensive implementation happened quickly. CEF´s business director Hannu Manninen describes the implementation and ease of use as competitive advantages. “WBS Productivity is an independent system, which does not require connections to automation or ERP Systems. This brings clear benefits to the customer compared to software solutions”, Manninen tells.
A sensor based system brings tangible benefits
WBS Productivity was taken into use with a warm welcome in Ojala Group. The sensor based solution enabled the utilization rate follow-up for independent machines in addition to the whole production line. Ojala Group has integrated WBS Productivity to its own internal intranet-network and brought monitor screens next to their every main machine. Now every machine user sees the utilization rate of their machine in real-time. The general experience is that the interest of the personnel towards their own work has improved.
Also the management has received WBS Productivity positively. The amount of manual reporting has decreased clearly, allowing everyone to focus in efficient work. One can see the state of production with a glance from the screen in the management office. In addition the system has plainly given tools and reasons for planning work shifts and breaks.
Factory Manager Jari Linnala is satisfied with the solution supplied by CEF. He can follow the start of the production first thing in the morning from his cellphone regardless where he is located. According to Linnala, it is great that the sensor based solution supplied by CEF suites to any machine from a power drill to the finest manufacturing machines, and the operational principles are never a problem for follow-up at any circumstances. “This enables the price per measured machine to be reasonable and the expansion is possible at any wished rate”, says Linnala with satisfaction.