Digital Transformation of Reporting Case Study
GEMBO (www.gembo.co) is a leading innovator in the world of SaaS Industrial IoT Platforms, with a proven track record of delivering cutting-edge solutions that help customers achieve their business goals. The company's platform uses a combination of IoT, machine learning, and AI to provide customers with real-time insights into their operations, enabling them to make better decisions and optimize their performance. GEMBO is committed to continuous innovation, and the company is constantly looking for new ways to use technology to help its customers succeed.
Customer Intro
The customer is a Tier 1 multi-billion dollar global manufacturing leader in the power, discrete semiconductor, and passive electronic components (PES) space. GEMBO has deployed a suite of innovative, cloud-based solutions to the customer, including Precare Cloud, Precare Edge, OEE Availability, Performance, and Quality packages. These solutions have been deployed to 70 machines across two factory floors, and the customer intends to scale the deployment across their entire Asia-Pacific footprint.
Problem
The customer's equipment engineering team has been managing the productivity of their machines through manual Excel reports. These reports are prepared by machine operators, checked and consolidated by supervisors, and then reported to management by factory floor managers. The customer needs to minimize or eliminate these manual reports to improve the accuracy of the reports and save on manpower costs.
The following are examples of manual reports that the customer needs to eliminate:
1. Calculation of the share of subcategories of Performance and Quality
2. Calculation of the percentage of Planned Downtime to Total Run Time
3. Graphical presentation of OEE Availability with Time Frame
These reports are time-consuming and error-prone. They also require a significant amount of manpower to create and maintain. By eliminating these manual reports, the customer can improve the accuracy of their productivity data and save on manpower costs.
Solution
After a technical discussion with the customer, GEM integrated the manual Excel reports into the OEE analytics framework. The team then implemented the following process:
- Define the customer requirements
- Gather the excel reports
- Create an output image showing changes in the analytics
- Define data to be collected
- Collect data from the customers
- Collect the data from customer
- Validate the completeness of the data based on the requirements
- Collect missing data
- Confirm with customer if all data are accurate and structured properly based on their requirements
- Prepare the design
- Overview
- Customer Requirements
- Use Case
- System Diagram
- Code Diagram
- Review and approval of the design
- Testing on Developer Environment
- Deployment to Production
- Customer acceptance
Results
The migration of previously manually prepared OEE reports to a digital format using OEE Analytics resulted in the following benefits:
- 100% savings on manpower costs, as the reports are now generated automatically and do not require manual input.
- 100% accuracy, as the data is collected directly from the machines and is not subject to human error.
- 100% time savings for management, as they no longer need to spend time reviewing and validating the reports.
- Improved decision-making, as the Operations Group can now access real-time data and insights to make better decisions.
- Increased efficiency, as the Operations Group can now focus on core tasks and not on data entry and reporting.
Conclusions
GEMBO Precare has a set of powerful data acquisition, analytics, predictive and OEE tools for manufacturing equipment. GEMBO Precare compiles critical KPIs that can be used to easily trace back which machine or machine subsystem is responsible for a low KPI score. GEMBO Precare is also able to make predictions at equal or better than humanly possible for machine maintenance to be scheduled before a failure occurs. But most importantly, unlike other market solutions, GEMBO Precare is able to deploy its own sensors independently from any machine controller and fully connect any machine data island to the GEMBO Precare Cloud at a fraction of the cost of a new machine; hence, saving manufacturers from having to make large and risky CAPEX and OPEX investments for new machines.
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