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GainSeeker Real-Time SPC Data Eliminates Costly Guessing
Technology Category
- Analytics & Modeling - Real Time Analytics
- Functional Applications - Remote Monitoring & Control Systems
Applicable Industries
- Aerospace
- Automotive
- Agriculture
Applicable Functions
- Maintenance
- Quality Assurance
Use Cases
- Predictive Maintenance
- Machine Condition Monitoring
Services
- Software Design & Engineering Services
- System Integration
The Challenge
Senior Flexonics - GA Precision, Wisconsin, faced a significant challenge in accurately determining the tool life for each of the thousands of tools used in their manufacturing processes. The Business Unit Manager, Phil Kapalczynski, doubted the claims made by tooling vendors regarding tool life but lacked accurate data to verify these claims. The existing method of tracking tool life was cumbersome, relying on paper records that were often incomplete or difficult to interpret. This lack of reliable data made it challenging to ensure that operators accurately documented tool failure and replacement, leading to inefficiencies and potential downtime. Kapalczynski envisioned a cost-effective, automated method to track tool life, identify problem tools, increase uptime, and eliminate second-guessing. Accurate data records were needed to hold vendors accountable when tools did not perform as promised.
About The Customer
Hertzler Systems is a company that specializes in providing seamless and accurate data acquisition solutions for various business enterprises. With over 30 years of experience, Hertzler Systems has built a large and diverse customer base across service, transactional, and manufacturing environments. Some of their notable clients include Consolidated Biscuit Company, Darden Restaurants, Pactiv Inc., McCormick & Company, and Hormel Foods. Customers choose Hertzler Systems for their software and services because they offer a good return on investment. The company's solutions enable clients to easily acquire data from any process, analyze it in real-time, and instantly notify process owners of any process variations. These capabilities help clients reduce costs, cycle time, errors, and defects while increasing profitability and customer satisfaction. Hertzler Systems' core competencies lie in their ability to provide accurate and efficient data acquisition and analysis solutions.
The Solution
Hertzler Systems provided Senior Flexonics with their real-time data collection software, GainSeeker. This software allowed operators to follow an easy procedure for accurately entering tool data into the system. Real-time email alerts were sent out when a tool failed, met, or exceeded its life expectancy. For instance, if a tool failed after making only 50 parts instead of the expected 500, an email alert would be sent to notify the relevant personnel. GainSeeker's data determined when a tool had reached its wear point, and machines would automatically shut down at that point to prevent scrap. This automated and accurate data collection method enabled Senior Flexonics to track tool life effectively, identify problem tools, and increase uptime. The implementation of GainSeeker helped set accurate tooling standards based on reliable data, significantly improving tool testing capability and overall operational efficiency.
Operational Impact
Quantitative Benefit
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