Company: Global manufacturer of high-performance automotive components
Goals: Optimize operations and comply with corporate Industry 4.0 initiatives
Increased equipment availability by reducing unplanned downtime
Provided scrap and downtime savings of over $1 Million over 2 - 3 year span
Automotive
Company: Global manufacturer of high-performance automotive components
Goals: Improve performance through scrap reduction
Increased machine tool life expectancy
Reduced scrapped parts from 7 - 10 parts per tool break to 0 - 1 scrapped parts
Over $230,000 savings per line annually
Automotive
Company: Global manufacturer of world class vehicles
Goals: Reduce unplanned downtime in critical bottleneck machining centers
Replaced 8 hours of unplanned downtime per machine with 3 hours of planned downtime
Increased equipment availability by reducing unplanned downtime
Over $1.1 million in cost savings in one year
Food and beverage
Company: Leading provider of equipment, processes and reporting systems
Goal: Improve productivity in large dairy farms
Reduced CIP cleaning time by 20 minutes per day
Over $38,000 efficiency improvement annually
Reduced chemical and water treatment usage
Food and beverage
Company: Leading design / build engineering and construction firm
Goals: Reduce unplanned production stops due to instrumentation failures and reduce overall project costs
40 fewer hours required for troubleshooting and commissioning
20 - 30% cost savings for instrumentation ($20,000 for this project)
Food and beverage
Company: Leading US cheese manufacturer
Goal: Streamline instrumentation replacement so technicians can work on other value-added activities
50% reduction in commissioning time
$10,000 reduction in pressure transmitter inventory
$300 savings per device
Food and beverage
Company: Designer, fabricator and installer of custom sanitary process systems
Goal: Improve operator and environmental safety as well as increase machine availability through CIP automation
Reduce wasted chemicals sent to drain
Prevent cross contaimination
Improves cleaning cycle time
Logistics automation
Company: One of the largest department store retailers in the US
Goal: Reduce downtime caused by jams and crashes on sortation conveyors in 10+ distribution and fulfillment centers
$250,000 annual savings for one location
Reduction in operation downtime
$30,000 savings on replacement parts
Steel industry
Company: One of the leading producers of steel and steel products in the US
Goal: Diminish unplanned production stops due to mill stand failures and reduce scrap rate.