Visibility & Production Control

About

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Executive Summary

Dale Evans, the president of EVCO Plastics, a custom plastic molding
manufacturer, wanted to track and monitor the molding status of
each of his 129 presses in eight facilities.

The Challenge

Companies often have a reactive approach regarding production control—they wait until a part fails QA inspection to find a faulty process or depend on opinions of what went wrong. EVCO Plastics wanted to take a more proactive approach by implementing accurate, real-time data collection on their 129 presses operating in eight plants in the United States and Mexico.

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Corporate Rebranding

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Website Redesign

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Amazing Result

Solutions 

SYSCON-PlantStar implemented Panorama®, their top-tier production monitoring system, in eight EVCO Plastics facilities. A Data Collection Module (DCM) at each injection molding press gathers OEE-related data and sends the information to a shared PC-based server. Each press is represented on screen with a status bar whose color indicates the status of the machine. If the molding process falls out of tolerance, the status bar changes and an audio page is announced
in the plant. The machine status bars are also displayed throughout the plant on video monitors. In addition, the system recognizes out-of-tolerance cycles, job status and many other variables and displays the information in easy-to-read screenshots.

Panorama’s job scheduler function enables managers to schedule jobs for every press. They schedule by part date, drag and drop orders from machine to machine, and schedule downtime. Managers can see bottlenecks and potential scheduling problems before they occur. Supervisors use the system to do SPC analysis, job costing and forecasting. Panorama’s open architecture allows EVCO Plastics to share plant floor data with its MRP system.

Initially, machine operators were hesitant to adopt the audio and monitoring systems. Now they see the system as a tool to proactively manage any problems. This system also enables machine operators to better understand how their jobs specifically impact productivity.