INDUSTRY

Manufacturing Sector

Risks
  • Lacked of real-time information on unscheduled downtime
  • Team lacking the ability to respond at the first time
  • Production affected

The Study

Our Client is committed to creating a better life and a better world, continuously contributing to the evolution of society and the happiness of people around the globe. Established in 1965, the company has a long-standing presence for more than 30 years and became the first foundation of the brands’ success in Malaysia. Their first plant is to manufacture household electrical appliances in Malaysia, namely Electrical Home Shower, Fan, Vacuum Cleaner, Electric Iron, Blender, Rice Cooker, Juicer, Food Processor, Bidet and Dish Dryer.

Today, as part of its ongoing commitment to sustainability, they aim to achieve the company’s ability by fully taking advantage of Smart Manufacturing capabilities. This is made possible with YNY’s GoDigital Solution by achieving Overall equipment efficiency (OEE) for their plant to increase operational & operation efficiency. Hence, allowing them to operate at -full production capacity.

OUR

CUSTOMER CHALLENGE

The Manufacturer lacked real-time information on numerous unscheduled downtimes due to Raw material insufficiency, Inadequate Production speed, and Quality related issues.

Production staffs were continually reacting to the unscheduled downtime, with the operation team lacking the ability to respond at the first time when there is any abnormality, causing the production unable to operate at maximum capacity to fulfill the scheduled demand.

OUR

SOLUTION

Turning Vision into Action 

By implementing an algorithm that allowed for the propagation of downtime codes from machine centers to the line, our YNY’s GoDigital solution proved to be a strong value proposition for this Japanese Manufacturer to accurately analyze their data and see what was impacting critical production operations. The solutions feature System Platform powered by MES Performance, Edge Computing & Computerized Maintenance Management System(CMMS).  

YNY’s GoDigital solution is used across all seventeen lines in Phase 1 implementation for the plant to great success. Ongoing access to pertinent information enables plant personnel to analyze production data, make informed decisions and implement successful solutions with  

  1. Operational dashboard to enable real-time situation awareness of production OEE and ANDON (Unplanned downtime) to assist in remote monitoring, reporting & increasing productivity by eliminating movement & gathering loss.
  2. Implement CMMS system to digitalize maintenance process workflow, reduce response time, handle corrective & preventive maintenance and spare part inventory management
  3. Implemented Work Order Management system to enhance planning and handle ad-hoc re-scheduling of Work Order due to manpower or material shortage
  4. Implement work instruction system to ease the training of new operators
  5. Integration with Telegram API to enable critical process notification thru a telegram 
THE

RESULT

Access to Accurate Data = Production Improvement 

The team was able to identify areas for improvements between unplanned downtime, equipment effectiveness, and labor effectiveness. With YNY’s GoDigital Solution, the Japanese home appliance maker can unify their data and real-time manufacturing information across the plant, enabling process optimization to drive operational efficiency.  

They are able to optimize employee performance by tailoring training based on hard data rather than subjective opinions. Line mechanics now focus on overall line performance rather than machine or operator-based issues by improving machine operator performance. The sustainability Goals are achieved through YNY’s  GoDigital solution to maximize plant efficiency.