Acatec Case Study (PDF) - Memex Automation

Case Study
Aerospace
www.memex.ca
Lean Implementation Precision Machining
Company Profile
Acatec S.L. is a European company dedicated to the manufacture of precision aeronautical components. An
experienced and quality focused enterprise, Acatec has established itself as a leader in aerospace manufacturing.
Their innovative production processes have propelled them into the vanguard of the European aeronautical
manufacturing industry. Acatec is a high demand, least cost provider to notable aerospace companies such as
Airbus, EADS Casa, Composites International S.A., CESA and AC aries complex s.a. and indra.
Business Situation
Acatec is mandated to improving productivity throughout their operations.
Embracing new technologies, Acatec has set about overhauling their
complete process from the purchase of raw materials to the delivery to
clients. To that end, Acatec has implemented a management system for
warehouse and computerized control of production. Located in Spain,
Acatec must strive to continue to reduce costs and out-perform their client’s
expectations.
Technical Situation
Acatec needed to implement time saving, resource light systems to assist
in forward planning of work, gauging capacities and delivery times to meet
demanding delivery schedules. The challenge was in the lack of in-house
engineering and technology personnel to drive the initiatives. Though
Acatec had a seasoned, experienced manufacturing group, historically
manufacturing in Europe left the macro engineering and IT/technology
services to outside professional services companies.
Solution
Acatec spent considerable time researching local technology companies which could effectively provide automated
data collection products. Acatec soon recognized that in order to manage for productivity improvements and
efficiency, they had to first measure the actual events. The Lean team at Acatec fully understood the value of
consistent, reliable data in the form of metrics, such as OEE (Overall Equipment Effectiveness). Acatec needed a
technology company which would provide a turnkey system and who would provide installation of the equipment, as
well as the interpretation of the data, so as to make the adoption of the automated system relatively simple in
regards to continuous improvement. This process led to the selection of the Memex AxOEE software utilizing the
Ax9150 Universal Machine Interface for automated data collection.
Manufacturing Monitoring - OEE Solutions

Case Study – Continued
Acatec started a pilot project at its Madrid plant with two
machines in May of 2011 with a plan to validate the system
over a 60 day period. The resulting information was so
compelling that management determined the pilot a success
within a mere 4 weeks and proceeded to roll out a full plant
wide installation throughout their Madrid facility.
www.memex.ca
Acatec installed the Memex equipment in August 2011 and
then gathered benchmark data in September 2011. They
then made procedural changes to their manufacturing
processes through October – December 2011, and found
that within the first 3 months, they were able to improve efficiencies 11% across their complete plant. They have
undertaken many initiatives to make the OEE information highly visible, including running the Memex system up on
the large screens displayed throughout the plant.
From start to finish, Acatec had rapidly engaged and deployed the Memex Productivity system within 90 days of
selection. The Lean team had quickly assessed the value of the information and applied it to:
Integrated ERP connectivity providing automated loading of schedules critical to job prioritization.
Ability to load work orders, operator lists, product standards, streamlining job validation.
Identified bottlenecks in the production process.
Began creating a valuestream process by which to enhance efficiency.
Timely movement of inventory through the plant so as to not have machines starved for material.
General awareness, reaction and visibility of production metrics for efficiency from all staff.
Advanced reporting with text and email alerts to key
management.
Their Lean manufacturing engineers made a number of operational
changes and were able to see the results rapidly. Now they have more
capacity on a daily basis and producing parts in record time, so revenue
is higher and costs are down.
Benefits
This effective deployment of real-time OEE automated data collection has resulted in the following benefits:
Increase in operational equipment efficiency of over 11% in 3 months’ time.
Planning is easier with graphical tools and real-time visibility of production.
Alerts of machine related events both automatically from machine and operator gave faster response.
Eliminated the requirement for all overtime associated with critical machines.
Revenue is higher and costs are down giving them a competitive edge in line with their mission statement.
Reporting visibility by machine, operator, work order, part and many other variables.
Have full traceability of all machine events for aerospace industry compliance.
Increased gross revenue and bottom line profit, beyond their initial projections.
Ability to complete a higher volume of work utilizing the same set of resources (equipment and personnel).
Products and Services Deployed
Memex AxOEE software
Ax9150 Universal Machine Interface
Handheld HMI for downtime recording
Memex is considered the “Go To” supplier for OEE and connectivity
Manufacturing Monitoring - OEE Solutions