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Maintenance efficiency – automated

Egger Ltd at Hexham, Northumberland, UK, manufactures chip board and associated products on highly automated production lines. The programs within numerous manufacturing systems and controllers are vital to the resulting OEE of the company and require frequent back up, version control and automatic administration. Egger standardised on Versiondog software from SolutionsPT to undertake and manage this task.

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  • SUPPLIER
  • Auvesy
    AUVESY GmbH is a solid medium-sized enterprise based in Rhineland-Palatinate, Germany. The software versiondog offers worldwide a secure solution for version control and data management in industrial automation. This leading version control software is the basis to heighten production efficiency by reducing errors and downtime; and monitor and control automation projects.
  • INDUSTRIES
  • Construction & Buildings
  • FUNCTIONS
  • Maintenance
  • CUSTOMER
  • Egger is one of Europe’s leading wood based panel producers. With a product portfolio that ranges from decorative products, such as Melamine Faced Chipboard, Decorative MDF, Laminate and Edging, to construction products, such as Chipboard and OSB. Egger products manufactured at the 75 acre Hexham plant include EUROSPAN® chipboard, EURODEKOR® melamine faced chipboard and EGGER tongue and groove flooring panels.

  • CONNECTIVITY PROTOCOLS
  • SOLUTION
  • Versiondog in use by Egger at Hexham automates a great deal of maintenance tasks, such as recording changes and backup. Versiondog also provides a background infrastructure to the use of device programs to trouble shoot, implement continuous improvement and to simply stay in control. When there is a hardware failure all programs can be quickly restored, in the full confidence that they are the latest version. By its very nature Versiondog carries on working in the background, day in and day out; whilst it may not receive the visibility of OEE dashboards to senior management, the resulting KPI improvements will inevitably have a direct contribution from the company’s use of Versiondog. Egger has standardised its manufacturing technology across its entire operation, Versiondog being the solution for automation program version control. Versiondog has proved to be vital to the continuous operation of the plant as it automatically captures all changes made to networked controllers, and can be used manually to ‘log out’ a particular program, make changes, and then return it. This includes fully commented code which allows its use as a maintenance diagnosis tool to be much clearer and easier to work with.

  • DATA COLLECTED
  • Backup, Change Management, Maintenance Requirements, Overall Equipment Effectiveness
  • SOLUTION TYPE
  • SOLUTION MATURITY
  • Mature (technology has been on the market for > 5 years)
  • OPERATIONAL IMPACT
  • Impact #1
    [Efficiency Improvement - Maintenance]
    The administrative procedures for checking out and checking in a program were easy and effective, and they had become part of the maintenance regime at the plant.
    Impact #2
    Impact #3
  • QUANTITATIVE BENEFIT
  • Benefit #1

    Shortened MTTR (Mean Time To Repair) when unavoidable downtime does occur, resulting in direct and immediate beneficial effect on OEE KPI’s

    Benefit #2

    About 20 people on site at Hexham have access to, and regularly use, Versiondog.

  • USE CASES
  • Manufacturing System Automation
    Manufacturing system automation integrates software and machinery so that manufacturing processes are run autonomously through computer programming. The goal of manufacturing system automation is to minimize the amount of human assistance needed in the manufacturing process. These systems provide constant feedback loops and adjust controlling parameteres in response to feedback from PLCs and smart sensors installed on machinery. Sensors are commonly embedded in new equipment or can be installed on legacy equipment. Automation has been achieved by various means including mechanical, hydraulic, pneumatic, electrical, electronic devices and computers, usually in combination. The benefit of automation includes a reduction of costs related to labor, electricity, water, gas, and scrap, as well as improvements to quality, accuracy, and precision. Manufacturing system automation can also reduce changeovertimes, thereby enabling small batch size production and mass customization.
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