ARBURG’s ALS System Enhances Neoperl’s Production Planning

Neoperl in Malvern has been running its mould shop with better planning, greater visibility, and more data since implementing ARBURG ALS two years ago, which has helped the company run its machines more efficiently. ALS, Arburg’s Manufacturing Execution System, has given Neoperl’s experienced moulding team more visibility and control of the shop’s workings from the additional data.

More Data Gives Better Visibility and Planning

The system displays a real-time overview of all Neoperl’s machines on a large touchscreen on the shop floor, which is also accessible on tablets for remote monitoring and control. The plan table shows what every machine’s current and next job is, helping the team to plan and complete jobs, and provides information on OEE (overall equipment effectiveness), quality measures, piece rate, downtime, granulate levels, and machine faults. Alarms can be set to notify when lower limit settings are triggered.

It shows machine operating levels including temperature and pressure, and finish times mean that changeover times can be scheduled. The volume of data that ALS can track means it has been a great tool to assist management decisions.

 “ALS has improved our communications to allow our moulding & tool setting team to make decisions autonomously,” says Production Manager James Love. “They can see what jobs are coming next, they can make decisions based on that. Before ALS we didn’t have that visibility.”

The dash indicates if a job is running faster or slower than the optimum cycles of the machine. Fast running could lead to product quality concerns and even a risk to the machine’s operation – seeing these levels ensures the machines are working hard but are not pushed too hard.

“OEE has improved over time, having this more accurate data from ALS allows us to put a realistic target on OEE,” says James. Optimum machine utility is an important metric for Neoperl. “What’s the point in having a Porsche and not putting the best oil and fuel in it? You should aim to utilise everything in the machine to the best of its ability, to unlock the full potential of the machine. It helps us do that,” says James, adding, “Two years in, to return to running the mould shop without ALS would be a backwards step.”

About 70% of Neoperl’s moulding machines are ARBURGs but ALS is brand-agnostic and can process data from any IMM, meaning the entire shop is connected.

James is keen to praise the moulding and tool setting team who have bought in to ALS and use it daily. The success of this system is down to their commitment to using it, and changing their work practices with the information it provides.

What is the main difference compared with life pre-ALS?

“Now, when they arrive for work, everyone has a clear plan of what’s happening in the mould shop on the day. There will always be unexpected changes, but it gives you something solid and clear to work to. You know how many steps you’re looking at for a job, you know what the machine issues are. Before it was very manual. Notes were handwritten at the end of a shift, downtimes recorded on a clipboard for each machine.

“It was quite a big change and I’m surprised it went as well as it did, because some of the team were not used to using tablets. So they have done a very good job in getting on board and getting the best out of it.”

Neoperl specialises in designing and manufacturing technical mouldings for the water industry, including aerators, flow regulators and valves.

Read more news from ARBURG here.

Arburg
01926 457000
Email
Website