How SensFlo Helps Measure and Improve Efficiency Amid and Post-Pandemic
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Introduction
In today’s dynamic manufacturing environment, efficiency and productivity are paramount, especially during times of disruption like the COVID-19 pandemic. SensFlo, a leader in industrial AI solutions, partnered with Ricaurte Precision to implement advanced productivity monitoring systems. This collaboration aimed to integrate machine monitoring with ERP data, deliver real-time insights, and enhance overall shop floor performance. Here’s how SensFlo transformed Ricaurte Precision’s operations.
Company Background - Ricaurte Precision
Ricaurte Precision has been a trusted provider of precision machining solutions for over 30 years, serving top aerospace, medical device, and technology manufacturers. Based in Orange County, California, Ricaurte Precision offers cutting-edge machining services with advanced equipment such as 5-axis mills, live tooling lathes, Swiss screw machines, and wire EDM technologies. The company is AS9100D & ISO9001:2015 certified, committed to exceeding customer expectations through continuous technological investments.
Challenges
Despite their advanced capabilities, Ricaurte Precision faced several operational challenges:
- Integration: Seamlessly integrate machine monitoring with their ERP system to provide live productivity monitoring, bottleneck analysis, and job delay predictions.
- Real-time Monitoring: Ensure continuous 24-7 monitoring of shop floor productivity and send real-time alerts for idle machines.
- Support for Digital Transformation: Secure support from the shop floor for the vision of digital transformation and AI implementation to improve efficiency and profitability.
Approaches
1. Installing Machine Monitoring Solutions
SensFlo began by installing its machine monitoring solution across Ricaurte Precision’s diverse equipment lineup, utilizing MTConnect for compatible machines and vibration sensors for cost-effective monitoring of others.
2. Customizing the Dashboard
SensFlo collaborated with Ricaurte Precision’s leadership to design a customized dashboard that provided real-time performance summaries and alerts. This dashboard ensured management could quickly access critical information and respond to unexpected downtimes effectively.
3. Changing Shop Floor Mentality
SensFlo made efficiency data transparent and accessible to all shop floor employees through a dedicated user app. This app allowed machinists to monitor their performance in real-time and receive immediate alerts, fostering a culture of continuous improvement and accountability.
4. Integrating with Shoptech E2 ERP System
SensFlo integrated its monitoring solution with Ricaurte Precision’s Shoptech E2 ERP system. This seamless integration enabled comprehensive data collection, including Overall Equipment Effectiveness (OEE) and job-level efficiency metrics, providing a complete view of shop floor performance.
Results
1. Increased Productivity
Ricaurte Precision achieved a 200% increase in machine utilization and a 600% increase in part count, resulting in a threefold increase in productivity. SensFlo’s monitoring system and ERP integration allowed the company to precisely measure and optimize the impact of increased utilization on overall productivity.
2. Enhanced Real-time Monitoring
SensFlo’s solution provided continuous real-time monitoring of shop floor operations, enabling proactive issue resolution and maintaining high efficiency even during off-site meetings.
3. Improved Communication and Support
The transparency and real-time alerts facilitated better communication between machinists and management, aligning the team with the company’s digital transformation goals. This objective performance measurement system was well-received, driving commitment to continuous improvement.
Conclusion
SensFlo’s AI-powered productivity monitoring solutions have significantly enhanced Ricaurte Precision’s operational efficiency. By delivering real-time insights, accurate productivity projections, and seamless integration with existing systems, SensFlo has helped the company achieve remarkable gains in machine utilization and overall productivity. If you aim to optimize your manufacturing processes and ensure consistent productivity, SensFlo’s advanced AI solutions are your key to unlocking full potential.
