Drive Your Business to Success

February, 2015

Keep your manufacturing floor operation at full capacity with a first class Maintenance Operation.

Matt Brienzo, Jefferson Industries CorporationKen Keller, Revolution Group

Overview

Company Background

Future

Benefits

Path Forward

Existing Situation

Jefferson Industries Corporation6670 State RT. 29 N.E. , West Jefferson, Ohio 43162

Brief History of Jefferson Industries Corporation

Established in 1988

Stamping and Welding of Automotive Structural Steel

6 North America Manufacturing Locations

JIC Has Expanded 12 Times

12 Stamping Presses Over 550 Robots

Existing SituationComputerized Maintenance Management System(CMMS) and Downtime Analysis

CMMS

Downtime

OEE

Work Request

Data Recording Data Input Data Output Reports

PM Inspection

Schedule

Limited access

Man hours allotted for maintaining system.

Daily communication is difficult

Preventative Maintenance(PM) and Work Request

CMMS

Prod. Report

Data Recording Data Input Data Output Reports

Required 3 associates to get Data out

Errors may occcur at each step

Information from system is delayed

Downtime Analysis

ERP

Path ForwardPlexus Maintenance Module

Equipment List

Weld has over 1900 pieces of equipment

Stamping has less than 50 pieces of equipment

Equipment List Identify user defined fields

Equipment Type Equipment StatusEquipment Group

Used as a filter when searching, setting up workflow and/or using equipment log

”Type”, “Group”, and “Status”

Equipment List Used Excel template to “Upload”

Not all fields are required

!!Can not Re-Upload once ID is created!!

Equipment List Utilized “Linked Equipment” option

Allows “Parent” ID to be created

Used to reduce number of PM’s tracked

Preventative Maintenance 3 Parts to Preventative Maintenance setup

Maintenance Task, PM Schedule Frequency Types and PM Schedule

Preventative Maintenance Used as a single inspection point

Attaches to PM

Will show on Work Request

Preventative Maintenance Frequency Type used for PM intervals

PM can be scheduled off different criteria

Preventative Maintenance PM Schedule used to create checklists

Checklist is used as PM Inspection

After checklist is created, PM is scheduled

Preventative Maintenance Tasks can have attachments

Chose PDF to eliminate software compatibility problems

PDF Document

Document

Preventative Maintenance Various frequency types are used

When scheduling, certain fields are required

Preventative Maintenance Work Request require checking each task

If task is checked NG, “Note” must be entered

Can not complete Work Request unless everything is checked

Workflow Allows flowchart approach to Work Requests

Automatic notifications when conditions are met

Work Request Flow Chart

No

Yes Yes

No Yes

Weld Yes

Stamp. Yes

No

Work

Request

Complete

No

No

Is work

complete

Follow Up

Work

Request

Leadership

Review. Is it

OK?

Which

Department

Leadership

Reviews and

assigns

Leadership

Reviews and

assigns

Technician

completes

Leadership

reviews

Is work

complete

Technician

completes

Leadership

reviews

Work

Request

Generated

Is it a PMAssigned to

technician

Technician

completes

Anything

NG?

History of all maintenance activities

Allows quick communication between all members

Equipment Log

Recorded through Control Panel

User defined workcenter status’s

3 Levels of breakdown

Downtime Recording

Workcenter Log

Automatic Reporting

Drill Down to Equipment ID

Can also use Workcenter Log

Downtime Reporting

IntelliplexDowntimeEquipment Log

Benefits

Efficiency Cost

Data Input Data Output Reports

Schedules

PM, Work Request, Downtime Recording Production and Maintenance 1 system

Eliminate paperwork.

Reduced / Eliminated man hours

PLEX

Prod. Report

Work Request

PM

Work Request

OEE

Downtime

Improvements Efficiency

57

57

.4

57

.0

57

.0

58

.0

58

.0

58

.0

57

.0

57

.2

57

.2

57

.0

55

.4

55

.8

56

.7

56

.1

55

.9

54

.4

54

.8

54

.7

55

.0

56

.3

56

.8

50

55

60

65

70

75

80

60.0%

65.0%

70.0%

75.0%

80.0%

85.0%

24Ki 25Ki 26Ki Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

Pa

rts

/ H

ou

r

OE

E

PPH Plan PPH Actual Zone #1 Zone #2 Zone #3 Zone #4 All

Goal: 73.5%

Parts Per Hour

Man hours reallocated

Forecasting

Workcenter status / Equipment Log

Future with Plex

Equipment ID assigned to multiple workcenters

Utilize Equipment History for development of future

equipment specifications

Automatic notification for workcenter status based on time

Thank youQuestions and Comments

Drive Your Business to Success

February, 2015

Weigh Scale Integration

Supporting Honda’s Line Side Labeling Requirement (L-MPR)

Assem

bly

Com

po

nents

Gro

up

Fluid Routing Solutions

Park Ohio Products

Bates Rubber

EP Cleveland

Delo Screw Products

Autoform Tool & Mfg.

PR

OD

UC

T L

INE

S

Fuel Systems

Extruded Service & Industrial Hose

Extruded Hose

Molded Rubber & Plastics

Big Rapids, MIOE Fuel Filler Manufacturing& Assembly

Big Rapids, MI

Tube Bending andPower Steering Assembly

Southfield, MI

Assembly Components Group HQ

Cleveland, OH

Hose Assemblyand Distribution

Cleveland, OHRubber InjectionMolding

Delaware, OHHydraulic FittingManufacturing

Ocala, FL

Rubber Mixing andHigh Pressure Hose Extrusion – Mfg. Plant

Lobelville, TNRubber & PlasticExtrusion andInjection MoldingMfg. & Assembly

Lexington, TNLow PressureHose Extrusion Mfg.& Assembly Plant

SHANGHAI, CHINA

Rubber Injection Molding and OE Fuel Filler Manufacturing & Assembly

Acuna, Mexico

Rubber Injection Molding and OE Fuel Filler Manufacturing & Assembly

Angola, IN

Fuel Rail AssembliesMfg. Plant

Customers: Honda, Chrysler, Ford, Nissan, Multiple Tiers

Shipping Destinations: 125 (Global Distribution)

Lobelville, TNRubber & PlasticExtrusion andInjection MoldingMfg. & Assembly

Business Situation

In September 2015 Honda will require their suppliers to meet a Minimum Process Requirements (MPR) for an accurate labeling process.

In November of 2014 Bates Rubber went live with Plex. During the implementation we reviewed 3 alternative solutions to meet this requirement.

1. PleXML 2. Checksheet with Weigh Scale integration 3. Checksheet with Gage integration (Standard Production)

Given the nature of the assembly process the Weigh Scale solution fulfilled more of the requirements.Prior to launch we decided to remove the weigh scale from scope and implement with a modified version of their existing process (counter board and 100% container inspection).

Pilot

Option 1PleXML either incrementing counter with capability to record container quantity and scrap or leverage a sensor on the counter boardCost: High cost (server, PleXML license, development) + cost of counter device, HMI, wiringPro: Remove human element to count parts as they are being put in a containerCon: Expense, new solution for ACG Does it meet Honda’s requirement: Yes

Option 2Checksheet with Weigh Scale integration Cost: Medium cost (37+ scales & terminals (risk of mislabeling if scales are shared))Pro: Meets Honda’s requirements and moves labeling to the work cell and eliminates the audit stationCon: Requires detailed part weight information and accurate tare weights for containers Does it meet Honda’s requirement: Yes

Pilot

Option 3Checksheet with Gage integration (Standard Production)Cost: Low, would only need a counter with USB interface (counts number of clicks)Pro: Provides count that final audit does not provide today. If small lot then supervisor would have to override failed checksheet in order to get label. Con: Systematically it does not prevent the operator from manually incrementing the counter or entering quantity directly into the checksheet.Does it meet Honda’s requirement: Unknown

Counting Rack

Counting Rack

Plex terminal & scale

Solution – Tie to workcenter status

Solution

Solution

After logging into the Control Panel, enter the Production screen. Click on the scale icon

Press the Read Scale button. No need to select any field

Solution

The weight of the container populates the Gross Weight field and calculates the Quantity based on the Piece Weight. Press OK when done.

The operator can perform a Resample before recording production if they choose to. They can enter the number of Pcs then press Resample which populates the Piece Weight field for the calculation.

Solution –Tie to container status

Time Line

February – Begin pilot on shop floor Gather process timing dataProve out scale solution with check sheets

June - Confirm workcenter and hardware design

July - Purchase Hardware

August - Launch

Benefits

• Meets Honda’s requirements.

• Counting rack plus weigh scale eliminates any chance of miscount.

• Moves labeling & verification to the work cell and eliminates the audit inspection station.

• Improves safety by eliminating stacking of containers that need to be inspected in a secondary operation that requires excessive lifting.

Q&A Session

1,000,000 Thanks!!