Case Study: Implementing accurate equipment lifecycle count readings to decrease downtime and increase product quality
Canadian Autoparts Toyota Inc (CAPTIN) is a wheel manufacturer located in Surrey, BC. They were the first manufacturing investment by Toyota in Canada.
25 wheel models, past and current
Annual manufacturing capacity of 0.8 million per year
Issues with wear rate recordings resulted in decreased product quality, essentially causing rejects.
As part of their dedication to continuous improvement, Alliance Power was contracted to implement a permanent change to their manufacturing process that would resolve their product quality control issues.
Our goal was to design, implement and commission the machinery component wear rate data automation addition to their manufacturing process.
We ensure that we are following all of our clients protocols, procedures and guidelines.
We understand the importance of minimizing downtime for CAPTIN's manufacturing process while providing the highest level of automation and integration programming to ensure that our work does not cause any errors to their process that could potentially hamper their production schedule.
Machinery Wear Rate
Machinery components that are cycled frequently wear down over time
Usage counts between production runs of the process equipment at CAPTIN was recorded manually on pen and paper
Automated recordings were required to provide accurate data to the maintenance department
Part Replacement Frequency
Inaccurate wear rates resulted in machinery components being replaced either early or late
Improper part replacement frequency can result in replacing components too late, or too early
Component replaced too early results in over spending
Component replaced too late results in decreased production quality
Late component replacement caused strings of product rejects which failed CAPTIN's rigorous QA process
Product rejects = lost resources and increased spending
With an 800,000 yearly production volume, downtime must be minimized at all costs
Any upgrades, changes, or modifications to control and process systems requires the utmost of care, diligence, and quality
Commissioning must be accomplished swiftly and with a high attention to detail
Analyze the full scope of the manufacturing process
Determine optimal life cycle of the machinery components that required wear rate tracking
Plan and prepare programming strategy with CAPTIN that would result in minimized downtime
Implement, commission and troubleshoot part number usage count sequences