Toyota
CAPTIN
Case Study: Implementing accurate equipment lifecycle count readings to decrease downtime and increase product quality
Overview
Canadian Autoparts Toyota Inc (CAPTIN) is a wheel manufacturer located in Surrey, BC. They were the first manufacturing investment by Toyota in Canada.
-
25 wheel models, past and current
-
Annual manufacturing capacity of 0.8 million per year
Issues with wear rate recordings resulted in decreased product quality, essentially causing rejects.
As part of their dedication to continuous improvement, Alliance Power was contracted to implement a permanent change to their manufacturing process that would resolve their product quality control issues.
Our Solution
Our goal was to design, implement and commission the machinery component wear rate data automation addition to their manufacturing process.
We ensure that we are following all of our clients protocols, procedures and guidelines.
We understand the importance of minimizing downtime for CAPTIN's manufacturing process while providing the highest level of automation and integration programming to ensure that our work does not cause any errors to their process that could potentially hamper their production schedule.
Their Challenges
1
Machinery Wear Rate
-
Machinery components that are cycled frequently wear down over time
-
Usage counts between production runs of the process equipment at CAPTIN was recorded manually on pen and paper
-
Automated recordings were required to provide accurate data to the maintenance department
2
Part Replacement Frequency
-
Inaccurate wear rates resulted in machinery components being replaced either early or late
-
Improper part replacement frequency can result in replacing components too late, or too early
-
Component replaced too early results in over spending
-
Component replaced too late results in decreased production quality
3
Quality Assurance
-
Late component replacement caused strings of product rejects which failed CAPTIN's rigorous QA process
-
Product rejects = lost resources and increased spending
4
Downtime
-
With an 800,000 yearly production volume, downtime must be minimized at all costs
-
Any upgrades, changes, or modifications to control and process systems requires the utmost of care, diligence, and quality
-
Commissioning must be accomplished swiftly and with a high attention to detail
Analyze the full scope of the manufacturing process
Determine optimal life cycle of the machinery components that required wear rate tracking
Plan and prepare programming strategy with CAPTIN that would result in minimized downtime
Implement, commission and troubleshoot part number usage count sequences
Client Achievements
Accurate Machinery Wear Rate
95% Decrease in Product Rejections
20% Cost Savings on Replacement Machinery Components
