How RICHARDS INDUSTRIALS increased OEE BY 50% IN 12 MonThs & and - 257% ROI IN 5 MONTHS SUCCESS STORY | APRIL 2020 - forcam
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FORCAM – We Deliver Results in Productivity.
how RICHARDS INDUSTRIALS
increased OEE BY 50% IN 12 MonThs & and
257% ROI IN 5 MONTHS
S U C C E S S S T O RY | A P RIL 2020
“With the use of FORCAM‘s
Manufacturing 4.0 technology with MES
functionality, we increased productivity
by >50% within 12 months.“
Bill Metz, Vice President Operations
Richards Industrials
AT A GLANCE Overview Managing Peaks & Valleys
Name: Richards Industrials Richards Industrials is the parent company of six The American economy is undoubtedly one of
Industry: Automotive, Me- distinct industrial product lines: regulators and the largest in the world. Although there is an
dical Device, Energy / Oil & control valves from Jordan Valve; sanitary regu- assortment of factors that kindle its growth, the
Gas Equipment Supplier lators and control valves from Steriflow Valve; contribution of energy must not be overlooked.
Location: Cincinnati, OH ball valves and automated products from Marwin Energy consumption is closely associated with
Size: SMB Valve; high pressure - extreme low flow regu- economic growth and manufacturing activity.
Employees: 150 lators from LowFlow Valve; instrument valves The unprecedented decline of crude oil, the key
and manifolds from Hex Valve; steam traps and source of energy, has created opportunities and
steam specialty equipment from Bestobell Steam threats for American manufacturing. As spending
Traps. Richards meets customer needs with a on energy remains a key determinant of standard
wide range of new and proven manufacturing of living and a crucial component of manufactu-
technologies. Complete in-house CNC machining, ring expenses, the impact on the bottom line for
painting, assembly and testing, along with mate- publically traded and smaller privately owned
rial traceability and extensive quality procedures businesses is noticable. While smaller firms are
assures that Richards Industrials products exceed much more susceptible to these factors many
expectations. firms in related industries experience less robust
business given the current circumstances faced
Richards Industrials focuses on new product in the energy sector.
development, process improvements, lead time
reduction, on-time shipments and quality. Using Richards Industrials‘ business has been slowed by
proven techniques such as Lean Manufacturing, the Oil and Gas reductions but has continuously
Richards is dedicated to finding ways to improve invested in new product development, process
manufacturing processes, existing products, cre- improvements, lead time reduction, ontime ship-
ating new products, reaching new markets and ments and quality. By using proven techniques,
responding faster to customers. such as Lean Manufacturing methodologies,
productivity is expected to pickup with increased
Key markets include chemical, petrochemical, sales per employee and per hour worked.
pharmaceutical and food processing industries.
Other sectors include paper products, tire and
rubber, machinery and electrical equipment,
transportation equipment and energy industries.
FORCAM Inc. | 4030 Smith Rd. | Cincinnati, OH 45209 | USA | +1 844 236-7226 | www.forcam.com
Solutions in use:
Data Performance Document Schedule & ERP Adapter
Collection Analysis Control Dispatch Mapics (Infor)
BENEFITS Goal Multi-Phase Project
■ Objective process and The company is dedicated to finding ways to Phase-1: Machine Data Collection (MDC),
machine monitoring improve manufacturing processes, existing Visu-alization, Reporting, and Alerts
■ Productivity increases of products, creating new products, reaching new
+50% markets and responding faster to customers. As technological advances accelerate, markets
■ Processes Richards global network of representatives and expand, and economies become increasingly
synchronization and distributors is their own and their customers’ knowledge-based, it is imperative that businesses
standardization most valuable resource. With over two hundred become adept at collecting, analyzing, and making
■ Transparency for representatives throughout the world, there is decisions based on data. Richards Industrials,
production orders and a local representative who will provide hands-on headquartered in Cincinnati, started by imple-
machine cycles assistance with any application. Richards Indust- menting the FORCAM FORCE™ Manufacturing 4.0
■ Bottlenecks identification rials practices Lean Management philosophies for solution with MES functionality, which included
and analysis almost two decades. Investment in training and setting up real-time machine data collection,
■ Standardized key technology is key to retain talent and control cost. web visualization and alerting. This first phase
performance indicators (KPIs) included a 10-machine pilot helping operators to
■ Target-oriented become familiar with the user interface and data
performance measurement Manufacturing 4.0 in the FORCAM FORCE™ product suite. Phase 1
and benchmarking was rolled out to the remaining machine park
■ Visual management Old-fashioned methods to collect production and of an additional 21 machines 5 months after the
■ Overall plant efficiency machine data, which are time consuming and po- deployment of the pilot in late 2015.
continuously measured and tentially poised to human error, become obsolete
improved with modern Shop Floor Management technology. Phase-2: Order Data Management (ODM) with
Its purpose is to measure and visualize the perfor- Personnel Data, Product Data Management
mance of machines and assets ideally web-based (PDM) with DNC
and in real time. In result this leads to a transpa-
rent factory in which errors and waste can be eli- Richards’ computer numerical controlled (CNC)
minated immediately because production can be machine tools like simple lathes and Multi-Axis
virtually mirrored on any connected device. This machines with live tooling among others are
system allows companies like Richards Industrials equipped with a screen and keyboard for writing
to analyze the performance, availability and quali- and editing NC-programs at the machine that
ty of assets and optimize them instantly in a real connect to the in-house ERP system, MAPICS
world setting. from Infor.
FORCAM Inc. | 4030 Smith Rd. | Cincinnati, OH 45209 | USA | +1 844 236-7226 | www.forcam.com
“The biggest surprise: The ‘real numbers‘ on shop productivity
and machine utilization were not as high as managers thought.
We figured that our machines were cutting metal about 50% or
so over two shifts. It was more like 40% when monitoring first
started. It is now higher than 55% and climbing.”
Bill Metz,
Vice President Operations at Richards Industries
Results for Operators Order Data Management gives a comprehensive
overview of the orders in production, thus provi-
This significantly e nhances t he e ffectiveness ding the shop floor with order related infomation
of the launch process and lowers the risk of hu- to and from the Infor ERP system. Managers,
man error during program transfer. Automatic supervisors and workers are able to easily iden-
reports enable the company to receive data tify orders in production and status in the order
on product costs, operating states, and time. queue.
PDM is FORCAM’s technology tool within the
PLM process that is responsible for the ma- The central database also manages metadata
nagement and publication of the product data. including owner of a file and release status of the
The management of version control ensures that components. The package controls check-in and
everyone is on the same page and that there is no checkout of the product data to multi-user; carry
confusion during the execution of the processes out engineering change management and release
and that the highest standards of quality controls cotrol on all versions/issues of components in a
are maintained. Product Data Management also product; build and manipulate the product struc-
serves as a central knowledge repository for pro- ture bill of materials (BOM) for assemblies; and
cess and product history, and promotes integra- assist in configurations management of product
tion and data exchange among all business users variants — throughout the development. Phase-2
who interact with products — including project was rolled out to the remaining machine park
managers, en-gineers, sales people, buyers, and of an additional 21 machines 5 months after the
quality assurance teams on Richards’ shop floor. deployment of the pilot in late 2015.
Typical information managed in the PDM module
include:
■ Part number and description
■ Supplier/vendor
■ Vendor part number and description
■ Unit of measure and cost / price
■ Schematic or CAD drawing
■ Material data sheets
FORCAM Inc. | 4030 Smith Rd. | Cincinnati, OH 45209 | USA | +1 844 236-7226 | www.forcam.com
Solutions in use:
Data Performance Document Schedule & ERP Adapter
Collection Analysis Control Dispatch Mapics (Infor)
MTConnect® & Productivity Workforce Empowerment
MTConnect® is a manufacturing industry stan- Empowerment of employees is a key strategy in
dard to facilitate the organized retrieval of pro- next-generation leadership to affect engagement.
cess information from numerically controlled The key to workforce engagement is information.
machine tools. MTConnect® is a protocol similar And the key to information today is technology.
to languages with vocabulary or a dictionary. Mul- Monitoring the shop floor with technology means
tiple devices that all speak MTConnect® provide that all operators become an integral part of
similar data tags, which all mean the same thing. the production process for the reason to detect
Richards Industrials’ Mazak QTN400 quick turn errors and initiate correction of any deviation
400 lathe with live tooling is equipped with MT- from the target to ensure a more efficient and
Connect® and allows for an easy way to increase leaner production process. Empowerment of
productivity. these important employees is a key strategy for
Enough information is provided throughout manufacturing businesses as these translate
the production process, which allows for the directly into bottom line business results. The
calculation of Overall Equipment Effectiveness key component to this strategy is engagement
(OEE) which in turn helps evaluate how effectively through the power of information. And the key to
a manufacturing operation is utilized. information is technology.
FORCAM Inc. | 4030 Smith Rd. | Cincinnati, OH 45209 | USA | +1 844 236-7226 | www.forcam.com
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