It produces high quality technical mouldings, injection moulds for processing thermoplastics and thermosets and assembles structural assemblies, final products. It operates its production in two plants with a total production area of 10,000 m² in two production plants located in the Czech Republic in the towns of Budišov nad Budišovkou and Bruntál.
Production portfolio:
- Manufacture of press and injection moulds
- Production of technical mouldings of thermoplastic injection moulding technologies including 2K injection moulding
- Production of technical mouldings of injection moulding and direct thermosetting technologies, including BMC and SMC materials
- Component assembly including ultrasonic welding and laser and pad printing
- Service and repair of moulds and tools
Problems of the past:
- Limited data collection
- Paper-only record keeping, laborious evaluation
- Absence of the TPM method
- Absence of online data monitoring
- Problem with traceability of important production data
How did it all start?
- It was 2012 and Linaset had been looking for a solution for data collection and evaluation towards OEE for a long time. It was looking for a solution that it could hold in its hands and not be tied down by a stranglehold on source code and a prescribed form of visualization.
- In 2013, Linaset started to cooperate with a company from Žilina, which deals with the optimization of production and maintenance processes as well as coaching of key persons – IPA Slovakia. As INSEKO and IPA were already working on several joint projects, the ideal solution at that time was to carry out a reference visit to one of PM TOOLKIIT’s customers from Slovakia, who had already been using PM TOOLKIT for a long time.
- After the reference visit, a business merry-go-round was set in motion, which concluded that a Pilot Project for the monitoring of 8 selected injection moulding machines would be implemented at the Budišov nad Budišovkou plant.
- After the successful completion and evaluation of the pilot project, a roll-out to other key production facilities was gradually implemented.
Monitoring status today:
- 56 injection moulding machines – Arburg, Engel, KraussMaffei
- 25 thermosets – Arburg, Engel, KraussMaffei,CBJ, FAHR BUCHER, LAUFFER
- 9 CNC machines – Heidenhein – Toolroom
- 30 manual workstations – assembly
- 3 robotic workstations.
- The system is operated centrally on virtual servers
- Operators have +20 All-IN-ONE PC kiosks ranging in size from 15″ to 21.5″.
- Besides Operators, the kiosks are also used by Sorters, Masters, Qualitarians
- RFID technology on Kiosks – 125kHz
- New ideas from key users are continuously incorporated
- Integrated on the internal master system
General benefits of the implemented PM TOOLKIT solution
- Online production control, visualisation on large LCD screens in each hall
- Accurate credible and unbiased information
- Recording of all downtime
- Fresh OEE, quality is recorded continuously
- Introduction of the Operators’ Logbook
- Multilingual environment for the operator (Polish, Hungarian, Ukrainian, Czech)
- Analysis of production cycles reveals reserves
- Adjusted standards increased productivity after a few months of monitoring
- Optimized SMED – advanced analysis, basis for optimization
- Acceleration of reaction times of the Sorters
- Basis for payment of OEE-linked remuneration
- Detailed reporting
- Introduction of Autonomous Machine Maintenance as part of TPM, including sending out emails to defined persons in case a task is not completed
- Introduction of a module for electronic distribution of documents, directives linked to the login of a specific person with an RFID attendance card
- Incorporation of the established production process into an automated electronic system
- The PM TOOLKIT solution made it possible to realize complete “paperless production”, i.e. the complete digitalization of production by linking to the master system.
Customer statement:
Miroslav Slivka
Head of Main Production Linaset, a.s.
Machine networking, data collection and subsequent application of feedback to the process moves the entire production one level higher in efficiency and quality control. Nowadays, it is an absolutely essential part of production management with a direct impact on the efficiency of production processes and influence on the entire corporate culture.
