Communicating, sharing and analysing information in real time can derive manufacturing organisations a host of benefits, from increased flexibility and responsiveness to customer demands, to reduced costs and improved process efficiency. At MACH 2012, Seiki Systems will be demonstrating how companies can maintain and improve the flow of information between the top floor and the shop floor by utilising its integrated suite of manufacturing software modules.

The most effective implementations of a Seiki manufacturing solution are typically when the customer adopts a holistic approach to their manufacturing execution system, which ensures that data from shop floor can contribute directly to the effective planning and management of the production facilities and manufacturing processes. Seiki offers a wide range of modules, including ERP, production planning, SFDC, resource monitoring, shop floor communications and performance analysis; providing manufacturers with a flexible and scalable solution.

At MACH, Seiki will create a virtual factory environment to demonstrate how companies can bring together disparate islands of data to integrate and optimise essential business and manufacturing processes. In the 'Seiki Office', the ERP and Scheduler modules synchronise and co-ordinate business and production information in real time to create a realistic, optimised plan for the entire factory. Immediate updates of the latest manufacturing priorities can then be delivered to the shop floor.

On the 'Seiki Shop Floor' the Networked Manufacturing System (NMS) facilitates the integration to these top floor business intelligence systems. Industrial touch screen terminals will be used to view complete job information packs and work queues, monitor live resource status and collect works order data, providing direct updates to the Scheduler to close the data loop. It doesn't end there, as back in the office performance analysis modules provide an easy method of access, viewing and summarising all this manufacturing intelligence data to produce relevant management information, which can be easily shared and used to make informed business decisions.

Celebrating its 20th anniversary in 2012, Seiki has a wealth of experience of working with manufacturing organisations and technologies to help manage the entire works order lifecycle - from top floor to shop floor. A special anniversary edition of Seiki NMS, the core shop floor production management system module, is now available.
See us at MACH 2012 - Hall 5 - Stand 5345

See us at the UK's LARGEST regional manufacturing technology, electronics and subcontracting exhibition. Register now to attend and see the very latest technology, components, materials, products and services available in the South of England. Our team will be on hand to offer specialist advice that will improve your manufacturing processes and overall business efficiency - not to mention your bottom line!

Dates: 15-16 February 2012
Venue: FIVE, Farnborough
Visit us on stand 98

In 2012 Seiki Systems celebrates its 20th anniversary year. To celebrate Seiki is launching NMS 2012, a special anniversary edition of its core shop floor production management system module. The software is designed for companies looking to maximise productivity and get the most from lean initiatives by utilising a complete shop floor system to electronically distribute and collect manufacturing process data.

NMS 2012 draws upon Seiki's 20 years experience of working with manufacturing organisations and technologies. It is the culmination of valuable contributions from customers and partners that have informed the design and functionality enhancements of earlier versions, to make daily tasks easier and faster for users to perform. Stability and reliability are critical when it comes to managing manufacturing data, so whilst Seiki has focused on delivering a brand new user interface and new features, NMS 2012 has been designed to retain compatibility with previous versions of the software and customer data. New features include:

There is an increasing awareness of the tangible benefits to be gained from adopting technologies that can really support efficiency, process optimisation, cost control reductions and business growth throughout the manufacturing industry. NMS 2012 is designed to facilitate closer integration between the shop floor as a critical element in the business planning process and top floor business intelligence systems such as ERP, MRP and APS. It ensures that data from the shop floor can contribute directly to the effective planning, management and utilisation of production facilities.

Seiki will also celebrate its anniversary year at MACH 2012 with the company's largest stand to date, where NMS 2012 will be demonstrated live on the latest Senor industrial touch screen PCs and visitors will be able to see how Seiki integrates NMS with its finite capacity Scheduler and ERP modules to create a complete shop floor to top floor manufacturing solution

As 2011 draws to a close we reflect on what has been a very positive year all round. We are delighted to have welcomed many new companies to our family in 2011 and want to thank all our customers for their continued loyalty and support. We look forward to an even better 2012!

Our offices will be closed from 12:30PM on Friday 23rd December to Tuesday 3rd January.

www.worksmanagement.co.uk

Senor is a ruggedised industrial solution, ideally suited for delivering your full screen applications to the shop floor, enabling the user to view production information directly on screen, whilst also supporting data collection tasks and DNC operations.

Features include:

• 15" or 17" TFT display and resistive touch screen
• Intel Atom Dual Core Processor
• MS Windows XP Professional or MS Windows 7 Professional
• Ventless and fanless system
• Fully ruggedised - IP66
• Operating temperatures from -20ºC to +60ºC
• Shock tested up to 1G
• Aluminium casing with an industrial NANO coating
• Audio & microphone port

We also offer a choice of mounting brackets and poles to ensure the most suitable, space saving solution for your environment. Download a copy of the Senor Industrial PC Data Sheet for more information.

We'll have a Senor PC displayed on our stand at the AeroEngineering exhibition at the NEC in Birmingham, from 9-10 November. Make sure you register now and visit our stand 1213

Make it in Great Britain is a new campaign aimed at transforming outdated opinions of UK manufacturing. The campaign will culminate in an exhibition during Olympic Games time that will celebrate the successes of the manufacturing sector and encourage young people to consider a career in the industry. It is all part of the Government’s drive to encourage long-term economic growth and rebalance the economy away from the financial sector and towards a strong manufacturing sector.

Business Secretary, Vince Cable has called on UK manufacturers to help the Government find up to 30 'industry champions' to take part in, and support the Make it in Great Britain campaign. Mr. Cable explains, "Despite popular belief , Britain still does make things and has outstanding manufacturing companies, large and small. Our world-beating companies have an excellent reputation for innovation. I want our young people and those who hold outdated views of our British manufacturing to see that reality. That's why we're launching the Make it in Great Britain campaign. To help us do that I want our most passionate manufacturers, whether that's 'captains of industry' or those just starting out in their careers, to be our industry champions. With their help, we can modernise people's view of manufacturing and dispel the myth that 'we don't make anything in the UK anymore'."

The industry champions will be knowledgeable about manufacturing and will play an important role in challenging current myths about UK manufacturing. They will identify and publicise British manufacturing successes and act as advocates for the campaign and the future of British manufacturing. The campaign will be formerly launched in the coming weeks but if you would like to nominate yourself or a colleague to be an industry champion please visit www.bis.gov.uk/makeitingreatbritain.

Source: Department for Business, Innovation and Skills (National)
For more information and to read this press release in full, please visit the BIS website

Are you a savvy developer with great C# and .NET skills? Do you have SQL Server and UI experience? If the answer is yes we want to hear from you.

This is an excellent time to join us as we are about to embark upon a new product, taking our offering to the next level. For this role, we are on the lookout for an ambitious candidate with C#, .NET, SQL Server and T-SQL skills that has desktop application development and user interface design experience. For further information, check out our vacancies page.

Please note: this position has now been filled.

Four of the UK’s high-growth advanced technology markets converge under one roof, on 9-10 Nov, 2011, NEC, Birmingham

Aero Engineering 2011 is THE show exclusively for all businesses within the UK aerospace engineering sector – from R & D, design, test, supply chain, production, component, assembly & structures manufacturing, assembly, systems, quality, integration through to MRO Engineering. This will be our first time exhibiting at the show, demonstrating our full range of manufacturing execution software solutions.

Aero Engineering is co-located with three additional events: The Composites Engineering Show, Energy Engineering and UK Plastic Electronics Show. Registration for a free entry visitor badge provides access to all four shows. You can also attend as a delegate for £75 (early bird price. Rises to full rate of £95 after 30 Sept 2011)

Visitors are able to ‘search’ online pre-show, for relevant suppliers/partners either by individual show OR throughout the combined ‘Advanced Engineering UK 2011’ showcase. Similarly, you are able to pre-plan for meetings on-site via the B2B Networking portal.

Register online at www.aeroconf.com and make sure you visit the Seiki stand in Hall 20, stand number 1213

There are now only 10 months to go before the doors open to the UK’s premier manufacturing technologies show, to be staged at the NEC from 16 to 20 April 2012 and Seiki has already booked its stand, which will be our largest to date! The exhibition always provides us with the best forum for showing you our latest innovations as well as for hosting our customers and connecting with companies within the industry.

With British manufacturing leading the UK’s economic recovery, MACH 2012 is taking place at a pivotal time for all those associated with the manufacturing technologies sector. Space is selling fast, and a bumper show is forecast for 2012. MACH 2012 is gearing up apace, with more tooling companies, more machines and more space taken by exhibitors. Graham Dewhurst, Director General at the Manufacturing Technologies Association (MTA) which owns and runs the show, says,

“There is a real buzz about the show already, and exhibitors are looking forward to the ‘bounce’ in sales that MACH delivers, particularly as the UK’s economic situation improves and we see more capital investment. We’ve got some big names signed up and they’ve committed to bringing more machines and new hardware in 2012 - which is great news for our visitors.” (Source: MTA, 1 July 2011)

For the latest information on the exhibition visit www.MACHexhibition.com

Figures from MTA’s monthly survey of members for March indicate that business confidence has remained high over the first quarter of 2011. The results from the MTA’s new, more detailed, monthly survey also show that growth in UK sales has outweighed export sales; however a strong improvement in export business is expected in the second quarter of the year with respondents expecting overseas business to outperform domestic orders.

March marks the first publication of the new MTA Business Survey which continues trends of the previous Monthly Flash Survey and Quarterly Trends Survey. The new Business Survey reported a very slight reduction of new orders for March compared to February’s high level; however a strong improvement in order intake was expected by respondents in the second quarter of the year. In March, an increase in invoiced sales was reported by the greater part of respondents, with a stronger month-on-month increase for sales in the domestic market compared to the overseas market.

The majority of respondents indicated an increase in employment over the first quarter of 2011, however a large percentage of companies are reporting that a shortage of skilled labour has affected the level of activity in their business. Speaking about the figures Graham Dewhurst, the MTA’s Director General said: “Overall these are a reassuring set of figures. The first quarter has been a good one for our members who supply the enabling technologies to British Manufacturing – which bodes well for the sector as a whole. The news that they are looking forward to further increases in the second quarter is welcome too. But there are challenges on the horizon in the shape of shortages in skilled labour and international competition. There are export orders out there to compete for and our companies need Government to be straining every sinew to support their efforts.”
(Source: MTA, 3 May 2011)

For more information, or for the full report, please contact Kate Hulett or Paul O’Donnell at the MTA via khulett@mta.org.uk or podonnell@mta.org.uk

Are they myths, urban legends, bad habits or judgement errors? Whatever they are, the common mistakes that many manufacturers can make may be adding cost, wasting resources and labour, and frustrating customers.

Download an article from Seiki Systems that explores common dilemmas that manufacturers face and how software systems can be used to address process inefficiency and data inaccuracy. We reveal how this software can provide manufacturing organisations with the tools to enhance the integrity of the data on which strategic business decisions can be made, driving continuous improvement strategies to enhance the profitability of operations.

Download Article

The latest results from the MTA’s monthly survey of members show a positive swing in the number of manufacturing technology companies taking on new staff, with nearly a quarter of respondents reporting an increase in employment compared to last month. In addition, order intake grew by over 12%, taking the orders measure to the highest level since the survey began.

Results of the MTA’s monthly survey for February show that the trend for jobs in the sector continues to strengthen with almost 25% of respondents reporting an increase in the number of people employed, and the strongest balance for this question since the survey started nearly two years ago.

In fact MTA member, Renishaw, has recently reported that they have nearly 250 vacancies in the Group – just one illustration of what the surveys are telling us about an improving employment situation in the manufacturing technologies sector.

Net order intake recorded a month-on-month increase in February too, with this continued growth recording a new high for this measure. And, although invoiced sales were slightly lower than in January, the actual results show that the majority of companies reported an increase of at least 20% in invoiced sales.

Not surprisingly, business confidence is running at a high level, buoyed by the high level of inquiries which was significantly greater than in January, and at its highest level since June 2010. (Source: MTA, March 2011)

For further information please contact Paul O'Donnell at the MTA

Seiki Systems has announced record sales for the quarter ended December 31st 2010. With net sales up 35% compared to the same period in 2009, Seiki has secured the highest quarterly sales in the company’s 18 year history.

John Davis, managing director explains, “This success highlights our increasing focus on growing our market share by driving consumer demand for our solutions which aim to improve manufacturing systems and processes through the implementation of Seiki software. An integral part of this success has been an increased focus on expanding our reach into the UK and international markets through our distributor network. In 2010 the company realised an exponential growth in distributor sales, with year to date sales already exceeding all previous records.”

By focusing on user experience, data and information requirements, Seiki has evolved its software to help manufacturers address the complete works order lifecycle, from top floor to shop floor in a simple, easy to use and intuitive system. The latest version of Seiki NMS features a number of key enhancements that have been designed to provide users with an efficient and easy to use system to more effectively support daily work activities. These include the ability to update work in progress activity with a part count at any point during an operation and the ability to automatically adjust the outstanding quantities should a batch be only part delivered on receipt from a sub-contract operation.

The addition of DLoG industrial hardware has been a contributing factor to the company’s success by enabling it to penetrate new markets in the UK, targeting industries such as warehousing and logistics. DLoG continues to expand its range of industrial PCs with the addition of the XMT5/7 vehicle mount terminal and the slim MTC 6 industrial PC with the latest CFast technology and Windows 7 compatibility to provide greater performance and stability in industrial application. In 2011, the company will look to develop its reach into the fleet management arena with the addition of Advantech’s TREK-743 to its portfolio.

Despite the short month and adverse weather, December results from the MTA’s monthly survey of members show increased order intake and invoiced sales in UK’s manufacturing technology sector, setting a positive tone for 2011.

Results of the MTA’s monthly survey show order intake increased by 10% in December, and invoiced sales grew nearly 60%, supporting recent data published by the British Chambers of Commerce which showed that strong performance in the manufacturing sector during Q4 has helped boost the UK economy. Not surprisingly, business confidence is on the increase; however a dip was seen in the quantity of inquiries over December. This apparently seasonal reduction in inquiries may be attributed to the shorter working month. In regards to employment, the trend remains positive with a number of MTA members looking to recruit in the New Year.

In a rising market manufacturers should be looking for ways to further capitalise, and taking part in events such as the MACH exhibition, which will next be held in April 2012, providing an excellent platform to launch new products to market, and to meet new purchasers. Interested exhibitors should contact the MTA for more information. (Source: MTA, January 2011)

For further information please contact Paul O'Donnell at the MTA

Seiki Systems Ltd will preview the latest version of its Networked Manufacturing System (NMS) at the Southern Manufacturing 2011 exhibition in Farnborough. With an increasingly strong focus on what is happening on the shop floor, Seiki NMS remains one of the most flexible and comprehensive shop floor visual management solutions available to SME manufacturers in the UK today. Can you afford not to bridge the gap between your ERP or business system and those factory resources?

Due for release in early 2011, the latest version of Seiki NMS features a number of key enhancements that have been designed to provide users with an efficient and intuitive system to more effectively support daily work activities. By focusing on the user experience, data and information requirements, Seiki has evolved the software to help manufacturers address the complete works order lifecycle, from top floor to shop floor in a simple, easy to use and intuitive system. New features include an updated graphical user interface, interactive Factory Status and Machine Utilisation modules, open connectivity to Fanuc and Haas CNCs for data collection, Windows 7 compatibility and the software is written in the latest .NET development framework.

Taking a lean approach to manufacturing means eliminating waste and reducing non-value added activities for which fast, effective and simple shop floor communications are key. Seiki NMS is designed to collect data, disseminate information, increase visibility and automate routine activities, providing essential support in efforts to operate a lean organisation, whilst creating a trusted factory knowledgebase where performance and quality can be achieved through control and continuity.

In addition to featuring the latest software Seiki Systems will be showing its full solution offering, which includes ERP, graphical real time scheduling, SFDC, resource monitoring and DNC. The full Seiki manufacturing solution is now wider than ever before and can support customer requirements from order processing, to production planning, through to manufacturing execution and performance data capture, with flexible and configurable functionality supported by the experienced team of engineers. The Seiki team at the exhibition will be able to offer specialist advice to manufacturers looking to improve their manufacturing processes and overall business efficiency.

The software will be demonstrated on DLoG industrial touch screen computers, specifically the ITC 7 which is ideally suited to applications such as data acquisition in assembly and manufacturing. The combination of Seiki and DLoG software and industrial rugged computers provides users with a robust shop floor data collection, visualisation and communications solution.

Whether querying inventory stock of finished or unfinished goods in real-time, capturing operational data reliably, or displaying information such as works order status, a DLoG industrial computer is ideal. A lean 15” touch screen industrial client PC, the ITC 7 is ideally suited to applications such as data acquisition in assembly and manufacturing. The ITC 7 expands the existing DLoG portfolio of robust industrial computers for applications where space requirements are at a minimum and for IT technical implementation options such as the use of browser technology for machine terminals. Benefiting from a space saving depth of just 70mm, the ITC 7 also reduces the footprint on the shop floor.

Southern Manufacturing 2011 – 16-17 February – Farnborough, FIVE
Stand: R79

Register now

The UK's manufacturing technology sector ended the year in a bullish mood with the latest figures from the MTA showing another jump in orders. Both the levels of inquiries and order intake were up when compared to the previous month’s results.

The figures, which support earlier indications from across manufacturing as a whole, point to a business environment which is looking to invest in capital equipment. Companies in the manufacturing technology sector are taking advantage of the significant opportunities being created as the economy picks up and as British exports continue to enjoy a boost from the competitive exchange rate.

The level of orders is being maintained at the comparatively high levels seen since the summer, and business confidence is also holding up. The trend is positive in terms of jobs in the industry too, with several MTA members reporting increased numbers of vacancies.

Some exhibitors from the MACH exhibition held in June this year have attributed the upturn in business to the fruition of enquiries received at the show.

Graham Dewhurst, Director General of the MTA says, “The results from our survey are positive for the manufacturing sector with the indicators pointing to an optimistic start to 2011. The Flash survey provides an excellent temperature check of the industry - and we hope that the tough times are finally behind us and we can look forward to a prosperous future.”
(Source: MTA, December 2010)

See this article on the MTA website.

This seminar unites a wealth of experience in combining the latest technologies to combat the production challenges that the high precision manufacturing segment encounter every day. The demands for increased speed, accuracy, flexibility and quality whilst producing a wide variety of manufactured parts and small batches are not beyond reach, especially when your production capabilities of producing 24/7 unmanned, could really give you that competitive edge.

Seiki Systems along with Neuteq Limited, ABB Ltd and Haas Automation, will demonstrate how investing in flexible automation and software communications significant advancements on the factory floor can be achieved. Download the invitation and agenda

Date: Thursday 9th December 2010
Venue: ABB Ltd, Auriga House, Precedent Drive, Rooksley, Milton Keynes, MK13 8PQ
Time: Registration from 10am, Workshop commences at 10.30am and finishes at 3.45pm
Register here...

NEUTEQ has been working in the machine tool integration business for several years and have undertaken projects with a number of leading machine tool manufacturers. This has established them as a successful integrator of robotic production equipment that has been proven to improve working life, increased productivity whilst saving money for their customers. “In our journey into machine tool automation we have worked closely with ABB and we have integrated many machines with robots none more so than with HAAS by adding a robot to not just the M/C centres but to the lathes also”, explains Steve Kerr, Director of Neuteq. “Due to our success in this area we would like to make more manufacturers aware of how the robots and machines can work through the day and night unmanned using Seiki Systems technology, hence making a huge saving in today’s market that can be the difference between winning orders and losing orders by reducing the overheads”.

Haas Automation UK is the oldest, most established supplier of Haas CNC machine tools outside the USA. Haas UK was formed in 1991 and the company is known for redefining the industry with its award winning levels of service and support. During this open event Haas Automation will be demonstrating a low cost compact cell using their standard Mini Mill Vertical Machining Centre with an integrated ABB IRB140 6-axis robot with palletised loading and unloading allowing the machine to achieve the maximum flexibility with short batches or long running jobs but retaining the capability of manual loading if required and within the budget of restraints of every machine tool user.

Seiki Systems specialise in manufacturing execution software solutions, integrating the entire manufacturing enterprise to provide an immediate, visual and dynamic picture of the production process. Over the last 18 years, Seiki has established links to thousands of CNC machines at customer sites in the UK and internationally. Supported by our highly experienced team of UK based software developers and engineers, we offer customers solutions that can aid their efforts to operate a lean organisation where performance and quality can be achieved through control and continuity. “We believe that there has never been a more critical time to invest and secure manufacturing control and process advantage through the complete works order lifecycle. A robust manufacturing execution system can be a key differentiator for manufacturers in an increasingly competitive environment where the demand for speed, accuracy and flexibility is greater than ever before” explains John Davis, Managing Director of Seiki. Demonstrations will show how increased visibility and control can be achieved through finite capacity planning, effective shop floor communications and real time data collection and analysis.

Request further information and download the invitation and agenda

www.haas.co.uk
www.abb.com
www.neuteq.co.uk

The past six-months has seen investment stabilise or increase in manufacturing technologies according to the latest survey from the Manufacturing Technologies Association (MTA).

Looking forward over the next six months, 35% of respondents indicated investment would be higher in comparison to the previous six months, and only 5% said investment would be lower or much lower - hinting at a positive start for 2011. These results indicate that after a reduction in spending during 2009 and into 2010, businesses are looking to invest more to help reinvigorate the sector over the next two quarters.

The September survey also showed a high level of inquiries and consequently business confidence, following a seasonal dip over July and August. Although invoiced sales were unchanged compared to the August results, the majority of respondents reported a month-on-month increase in orders in September.

Employment results were positive in September with almost 20% of respondents reporting an increase in the number of people they employ, extending the run on this positive balance in employment to three months. (Source: MTA, October 2010)

See this article on the MTA website. For further information contact Paul O'Donnell at the MTA

Thanks to Seiki Systems advanced planning and scheduling with real-time machine tool monitoring software, the Kenard Engineering Group has the utmost confidence in the precision manufacturing support it provides to OEM companies in the defence, aerospace, communications and oil & gas sectors. With a 50,000 ft2 manufacturing site in Tewkesbury and a further 28,000 ft2 manufacturing and head office facilities in Dartford, Kent, Kenard is one of the UK’s leading privately-owned precision engineering companies. Both sites are accredited to the stringent AS9100 aerospace quality standard with a total of 140 highly qualified staff employed to support customers around-the-clock – 24/7 when required.

The manufacturing process is optimised using integrated manufacturing systems, including Kenard’s in-house developed ERP system. However, on the shop floor the company relies on Seiki Systems’ advanced scheduling, SFDC and machine monitoring software to provide accurate and detailed business information.

Operations Director, Matt Cornford, explains: “The KIDS ERP software controls customer orders, monitors purchasing functions and production control. As an example the system interfaces with Exostar, the e-procurement system favoured by aerospace and aero-engine manufacturers to keep their global subcontract suppliers informed of delivery requirements, to filter and highlight changes to their schedule on a weekly basis. It also interfaces seamlessly with Seiki Systems Real-Time Scheduler, allowing us to accurately measure our calculated delivery times against the customers’ expectations, which is crucial for our OTIF (On Time, In Full) figures.”

Designed to provide a high level of visibility and control in a manufacturing environment, Seiki Scheduler is a real-time finite capacity planning and scheduling system that plans each works order according to definable scheduling rules, current workloads and available capacity and creates a synchronised work-to list for each individual resource, including part numbers, individual operations, quantity, due dates and forecast finish dates. “It’s a very powerful tool,” says Matt Cornford. “Sometimes a customer requires a part urgently; we can tell instantly if that schedule change will affect any other jobs that we are doing for that customer as well as any other customer. Even subcontract operations like hardening and surface finishing are scheduled by the software, with further options to input sickness, holidays, planned maintenance and so on.”

Kenard also uses Seiki Systems’ NMS (Networked Manufacturing System) which provides a vital two-way communication link between the shop floor and the production control office. At the shop floor level it can display work queues and allow shop floor data collection (SFDC), machine monitoring, technical data distribution, DNC and probe data collection. While the office analytical suite offers a remote display of machine status and alarms, machine performance analysis, and individual job reports.

A variety of multi axis milling, turning and mill-turn machines are used by Kenard to produce the complex precision components its customers require. The CNC system of each machine tool is connected to a PC so that the Seiki software can facilitate bi-directional communications directly with both the machine and the operator. Production Manager, Danny Booth-Adams’ goal is to make the shop floor a paperless environment. He says: “I believe we will achieve this with Seiki Systems software. Operators get the NC code, set up sheets, drawings, tooling list and so on, just about everything that’s needed to complete the job.” Danny also uses Seiki Scheduler every day to balance the workload on the machines, reducing the time spent scheduling operations down to approximately one hour a day. “We used to require a full-time production scheduler/order chaser,” he says. “With Seiki Systems integrated with KIDS, we now know exactly where we are with any component batch. If a machine does stop it obviously affects the planned schedule. The graphical feedback and reporting provided by Seiki Systems allows me to adjust the plan, such as moving production to another machine, and I can visually check if the change will make a positive difference before I commit to it. As we consider our production capacity as one entity I can even move work to Tewkesbury to hit customer deadlines and gain even more efficiency.”

Using Seiki Monitoring software the machines’ status for both Tewkesbury and Dartford is displayed on large plasma screens in the production office. However, a recent MoD contract required even more control, and Seiki Systems again provided the solution. Matt Cornford explains: “Our customer has a very tight schedule for the delivery of precision machined electronic enclosures. So tight, in fact, that we had to have a spindle up time of better than 90 per cent. To achieve this Seiki Systems provided an application for our iPhones, replicating the graphics shown on the screens in the planning office and allowing us to see the exact status of every machine. The loading and operation of the five-machine FMS (Flexible Manufacturing System) in Tewkesbury was key to this project, as it can run for up to 35 hours unmanned. The monitoring provided an essential management tool, keeping everyone focused on this important contract and any spindle stoppage promoted an immediate response via the inbuilt NMS alert mechanism.”

As a privately-owned company, Kenard Engineering has always been committed to investing in its facilities, purchasing three new machine tools during the recession. Precision capabilities include turning up to 930mm diameter and simultaneous 5-axis machining, with machines programmed offline using the latest CAM software. Tewkesbury takes the company’s abilities even further with sheet metalworking capability, precision fabrication and electro mechanical assembly, as well as additive manufacturing with epoxy resin and carbon fibre. And, thanks to a recent investment, powder coating and painting can be carried out in-house. This ensures the company meets both the quality and delivery expectations of its customers.

Matt Cornford knows that investment and financial stability are important measures for customers in the sectors supported by Kenard Engineering. “Many of our customers carry out surveys every three months to check these parameters. As a privately-owned company we own our buildings and machine tools, and have a constant manufacturing technology investment programme to support our people.” Seiki Systems certainly provides that support, working with the huge volume of data required to run a successful manufacturing operation like Kenard Engineering. The complex components, often produced from difficult to machine material such as titanium, Inconell and duplex stainless steel, are required in low volumes. A batch of more than 60 is considered a long run so the company has engineered solutions to operate efficiently even down to a batch of one. Scheduling this low volume, high variety mix is very demanding but Matt Cornford states: “Using Seiki Systems has increased our efficiency by 10 to 15 per cent and puts us firmly in control of the results expected from the shop floor.”

He concludes: “When you lose time on a machine tool you can never get it back. Our spindles rarely stop and we have high expectations for the efficiency of each machine tool, you have to for a quantifiable return on your investment. We could not have achieved what we have without Seiki Systems, and the software even provides you with the feedback to show that you have made a positive impact on the business.”

www.kenard.com

Our USA partner, Jobpack Inc are exhibiting once again at America's largest manufacturing show IMTS.

Dates: 13 - 18 September 2010
Venue: McCormick Place, Chicago

Visit IMTS 2010 and JobPack in booth E3850 to see the latest Scheduling, ERP and Paperless Manufacturing Technology, along with best practices for deploying this technology and the opportunity to speak with the JobPack team.

After IMTS 2008, 88% of the attendees said they were successful in finding specific products or solving specific manufacturing problems.

IMTS 2010 is the only event where you can see and compare the world of computer-based manufacturing technology side by side. A completely interactive experience, you can see, touch and operate systems.

At a time when manufacturers are focused on getting the most out of what they have and being poised for future opportunities, it's critical to learn from others who have been successful. The following are just three initiatives, all available from Seiki Systems and JobPack Inc, from which you could see real benefit:

• On Time work order deliveries.
• Active alerts when jobs run behind time or will go late.
• Paperless Manufacturing to provide all manufacturing data at the point of use.

You will return from IMTS with entirely new knowledge that can serve you for years to come!

Click on www.imts.com and build your IMTS trip using "myShow Planner" to build your route, create a time efficient plan and ensure JobPack is part of the agenda. Using this will give JobPack your contact information so we can start a dialogue in advance of the event.

If you are unable to attend the exhibition but would like more information about or to see a demonstration of any of the products that will be exhibited at the show please contact our UK team on 01273 680411 or email sales@seikisystems.co.uk

ERP | Scheduling | W.I.P Tracking | SFDC | Paperless Manufacturing | Machine Monitoring | DNC | Analysis

Visit the JobPack website
Visit the IMTS website

July saw levels of orders and sales in the manufacturing technology sector broadly maintained according to the latest survey from the Manufacturing Technologies Association (MTA)

This month the value of order intake fell slightly, though the cumulative trend remains high. Invoiced sales increased in comparison to the June figures with the majority of respondents reporting a rise in sales, taking the cumulative trend to its highest level for four months.

The balance for business confidence remains significantly positive despite feedback that the level of inquiries has fallen. For some businesses, the fall of inquires in July could be attributed to peak of business interest following MACH2010 which was staged in early June.

Meanwhile, July saw the first positive balance for jobs, although the majority of respondents reported no change in their employee numbers. (Source: MTA, August 2010)

See this article on the MTA website. For further information contact Paul O'Donnell at the MTA

Seiki Systems and DLoG (UK) have announced that their first quarter figures were up 27% compared to the same period in 2009. Since joining forces in May 2008 Seiki Systems and DLoG (UK) have experienced steady growth in sales of their manufacturing software and industrial hardware solutions, despite the UK experiencing one of its worst financial crises in 2009, which saw a general decline in manufacturing IT sales.

John Davis, managing director explains, “2009 provided unique challenges for the manufacturing sector. We took the approach of continuing to invest in growing our business with the view that we would then be fully prepared to take advantage of the upturn in the economy when it came. To this end we have developed new partners, both in the UK and Europe, appointed a business development manager to grow sales of DLoG industrial hardware in the UK and expanded our software development team. The end of year results reflected our belief in the quality of our products and services and concerted efforts by the team to continue to deliver solutions that meet the changing requirements of our customers. This combined with such promising first quarter results and a highly successful MACH exhibition, it promises to be an exciting year.”

Feedback from the exhibition suggested an increasing focus on what is happening on the shop floor in order to execute the manufacturing process more efficiently and economically. Seiki’s Networked Manufacturing System (NMS) remains one of the most flexible and comprehensive shop floor communications solutions available to SME manufacturers in the UK today and MACH was the first time Seiki NMS has been demonstrated on DLoG industrial touch screen computers, specifically the ITC 7 which is ideally suited to applications such as data acquisition in assembly and manufacturing. John Davis continues, “The strength of our portfolio lies in its modularity and the ability to address the complete works order lifecycle, from top floor to shop floor. As feedback from MACH confirmed, visibility and control of all stages of the manufacturing process is becoming increasingly critical and this is what our solutions aim to provide.”

Visit the DLoG website

Seiki Systems will be exhibiting for the first time at the Farnborough International Airshow as part of the Manufacturing Technologies Association (MTA) stand. Seiki will have a member of staff in attendance during the week to answer any questions that you may have.

Visit us in Hall 1, Stand B4 view floor plan
Show Dates: 19-25th July 2010

Visit the Farnborough International Airshow website to purchase daily trade visitor passes

Seiki Systems is delighted to have been shortlisted once again in the 'Best Service and Support' category for the MWP 2010 awards. The biennial MWP Awards are the highest profile fixture on the advanced manufacturing technology calendar and are devised to recognise and applaud outstanding achievement in the design, manufacture, supply, management and use of machine tools, production equipment and services. Kenard Engineering has also been shortlisted in the 'Best Subcontractor - Machining' category. Winners will be announced at a ceremony on June 8th - during the MACH exhibition week.

DLoG (UK) will present its new DLoG ITC 7 for the first time at MACH 2010. DLoG has expanded its range of 15-inch terminals with the introduction of the DLoG ITC 7, a lean touch screen industrial thin client PC for data acquisition in assembly and manufacturing. Sharing all the core features of the IPC 7, this new computer is even more suitable for a manufacturing environment where a reduced footprint on the shop floor, lower costs and flexible IT technical implementation options such as the use of browser technology for machine terminals, are needed. The ITC 7 unifies the advantages of the existing range of DLoG robust industrial PCs with the low TCO of classical Thin Clients.

The DLoG ITC 7 has been designed for reliable operation in harsh environments at low operating costs. The Intel® Celeron® M based system is protected against vibrations and against dirt and water, currently meeting IP54 protection class with testing underway to certify compliance up to IP67. The ITC 7 comes with a space-saving depth of just 70 millimeters and at the same time allows fast access to the housing protected interfaces. USB devices such as memory sticks or input devices can be used quickly and easily thanks to the easy-access service lid, where access to the service USB interface of an installed ITC 7 is simple and secure. Even access to the Compact-Flash® card is effortless. New data can be transferred in a very short time or the system can be configured using a USB keyboard. The combination of flat stable housing and protected, easily accessible interfaces is at the top of the wish list for many customers. The newest member to the DLoG product family becomes the ideal product for secure and transparent working in demanding environments.

DLoG is able to offer a tailored solution configured to customer specifications across all the key variants, such as memory size, operating system, chassis, processor, etc. The ITC 7 is also available with stainless steel housing for use in food processing and pharmaceutical manufacturing environments.

MACH 2010 will be the first time that Seiki Systems Ltd and DLoG (UK) Ltd have exhibited together since joining forces in May 2008. The combination of Seiki and DLoG software and industrial rugged computers provides users with a robust shop floor data collection, visualisation and communications solution. MACH 2010 will be the first chance to view the latest version of Seiki NMS – a complete shop floor communications solution - with overall system speed and performance enhancements and a brand new user interface, demonstrated on DLoG touchscreen IPC terminals.

Taking a lean approach to manufacturing means eliminating waste and reducing non-value adding activities for which fast, effective and simple shop floor communications are key. Whether querying inventory stock of finished or unfinished goods in real-time, capturing operational data reliably, or displaying information such as works order status, a DLoG ITC 7 industrial computer is ideal. The terminals support the delivery of essential business information direct to the operator at the point of use, providing them with a real time view of what is happening in production, with a view to increasing efficiency and productivity.

MACH 2010 will be the first time that Seiki Systems Ltd and DLoG (UK) Ltd have exhibited together since joining forces in May 2008. The combination of Seiki and DLoG software and industrial rugged computers provides users with a robust shop floor data collection, visualisation and communications solution.

Seiki Systems will be showing its full solution offering, which is now wider than ever before and can support customer requirements from order processing, to production planning, through to manufacturing execution and performance data capture, with flexible and configurable functionality supported by the experienced team of Seiki and DLoG engineers.

With an increasingly strong focus on what is happening on the shop floor, Seiki’s Networked Manufacturing System (NMS) remains one of the most flexible and comprehensive shop floor communications solutions available to SME manufacturers in the UK today. Taking a lean approach to manufacturing means eliminating waste and reducing non-value added activities for which fast, effective and simple shop floor communications are key. Seiki NMS is configured to collect data, disseminate information, increase visibility and automate routine activities, providing essential support in efforts to operate a lean organisation, whilst creating a trusted factory knowledgebase where performance and quality can be achieved through control and continuity. MACH 2010 will be the first chance to view the latest version of Seiki NMS with overall system speed and performance enhancements and a brand new user interface, demonstrated on DLoG touchscreen IPC terminals.

Whether querying inventory stock of finished or unfinished goods in real-time, capturing operational data reliably, or displaying information such as works order status, a DLoG industrial computer is ideal. As well as featuring the proven DLoG IPC rugged industrial computers, DLoG will also be showing the DLoG ITC 7 for the first time. A lean 15” touch screen industrial client PC, the ITC 7 is ideally suited to applications such as data acquisition in assembly and manufacturing. The ITC 7 expands the existing DLoG portfolio of robust industrial computers for applications where space requirements are at a minimum and for IT technical implementation options such as the use of browser technology for machine terminals. Benefiting from a space saving depth of just 70mm, the ITC 7 also reduces the footprint on the shop floor.

The combination of Seiki and DLoG has enabled the Group to extend its ability to deliver innovative solutions, high quality services and create a synchronised IT environment by linking shop floor activities to top floor production driven business processes to enable companies to execute the manufacturing process more effectively and profitably. A re-branded Seiki portfolio will be launched at MACH, and will incorporate Seiki ERP, Seiki Scheduler, Seiki NMS, Seiki SFDC, Seiki Monitoring, Seiki Jobpack and Seiki DNC.
MACH 2010 – 7-11 June - NEC Birmingham

Hall 5, Stand 5292

Electronic and mechanical torque measuring and calibration equipment for critical applications is supplied by Norbar Torque Tools to just about every industry sector. These include the power and wind turbine industry, MoD, mining, oil & gas including subsea pipeline joints fastened by remotely operated vehicles, through to the International Space Station where a Norbar torque multiplier is used to actuate an emergency exit hatch. To meet the demands of this varied customer base the company relies on advanced production control software from Seiki Systems to enhance communication and increase visibility throughout the organisation.

A family-owned business, Norbar has been manufacturing torque tools for nearly seven decades and has just won its second Queen’s Award for Enterprise. Its Banbury facility is the main manufacturing headquarters of Norbar and here it employs just over 200 people, with the machine shop and other key manufacturing areas run on a day and night shift.

Manufacturing manager, Martin Reynolds, says: “The directors have a rolling strategic plan which highlights the company’s development for the next five years. Over the last couple of years we have exceeded the plan in terms of growth, and we intend not only to increase sales, but through continuous improvement become more efficient and effective throughout the company. The business is very focused on continuous improvement with a dedicated team that works in conjunction with the staff in various areas to look at ways we can improve all processes and procedures.”

With manufacturing set up in cells, senior cell leader Neil Bennett recalls how the company used an MRP system with infinite capacity planning and very often found the machines loaded to 200 and even 300 per cent. “We applied some shift working and overtime but we clearly could not meet these loading targets,” he says.

As the company investigated different processes to improve efficiency it started to work on a Kanban system as well as works orders. This caused a priority conflict between the works orders generated by the sales and forecasts within the MRP system and the Kanban requests generated by cells consuming stock.

Martin Reynolds explains: “Working to a forecast can lead to producing parts you don’t require which uses capacity in the machine shop. This was one of the issues which prompted the change to a Kanban system which would promote making parts we actually needed. This situation has been exacerbated during the past two years when we had a growth of over 25 per cent.”

Norbar was not just facing production control issues it was also struggling with corrupted transfer NC code on the shop floor. An early advocate of DNC technology the company had linked all of its CNC machines via a system that relied on a complex switch box, which was temperamental. Following an extensive review of the solutions available Seiki Systems was called upon to install its robust DNC file transfer software and graphical Planning Board, both of which made dramatic improvements for the company. Neil Bennett says: “After installing the Seiki Systems DNC package we now have the confidence that NC Programs will be transferred to the machines on the shop floor without any data corruption.” The Planning Board software provides a real-time dynamic view of the work-in-progress on the shop floor. “Installing Seiki Systems’ Planning Board has given us a much better insight of what we can do on the shop floor on a daily basis. Jobs are loaded onto the relevant machines and the software provides a predictive graphical view of the capacity status,” explains Neil Bennett

From its sales forecast data Norbar’s management team plans production for the shop floor up to two weeks ahead. Once that has been done the Planning Board software provides the cell leaders with a visual capacity check and the capability to alter the production sequence within predefined parameters. “They can drag and drop work from one machine to another to optimise their cell using the visual feedback provided by Seiki Systems Planning Board. It gives ownership to the cell leaders within achievable parameters,” Martin Reynolds states. Neil Bennett goes on to say: “One of the most frustrating things from a machine operator/setter’s point of view is spending time setting up a job on a machine, and changing to the next job only to find the third job is virtually the same as the first one. Planning Board gives a clear view ahead and lets them manually identify and group together jobs of a similar set up.”

Up until 18 months ago Norbar also operated a toolroom, which has been changed to an ‘Engineered to Order’ (ETO) cell, and this department suffered the same pull on its resource with works orders, production Kanban and the engineering department requesting time for prototype development work. With demands from three different areas, the work tended to get done for whoever shouted the loudest. Martin Reynolds says: “From the positive results achieved using Seiki Systems Planning Board in production we decided to enhance the solution by installing the Seiki Scheduler, the company’s comprehensive finite capacity scheduling software, in the ETO cell as this cell requires more controlled definition of every resource such as machines and people. In the production facility you have jobs passing from one cell to another for different operations to be carried out; in the ETO cell they tend to be jobs that are done from start to finish. So we had to have the ability to break down each element for every part.”

Feedback is crucial to measuring the performance of any manufacturing operation and as such Seiki Systems Machine Tool Monitoring software has been specified for all of the company’s newer machine tools as it lets Norbar see exactly what is happening on the shop floor. Capturing live manufacturing data provides real-time feedback for the Planning Board and also allows Norbar to make efficiency gains in set ups and changeovers, which means that the jobs that are causing the biggest problems can be targeted by continuous improvement activities.

“All new machines are automatically monitored for spindle run, alarms and power off. If the spindle is not running it defaults to waiting and the operators have a sub status within waiting that can be manually updated. This is keyed in at terminals located within each cell. We check and report on our efficiency for set ups, time spent waiting and production time, which can then be sub divided into waiting, inspection, no setter available, no raw material and so on. This level of detail captured in the data coming back from the shop floor resources via Seiki Systems software gives us a real insight as to where the problems are and what we need to do,” Neil Bennett explains.

Work queues can be downloaded from the scheduling server on to the shop floor terminal as required, informing the operators what needs to be produced next. For example, tooling support was introduced to increase efficiencies with tool offset measurement capability allowing tools to be pre set prior to any changeovers, which has a significant effect on the set up times. The tool stores controller has access to queue data via the Seiki system for all the machines, so he can look at whatever job is required next on any machine, look at the tooling suite required and pre kit it, usually two hours before the changeover occurs.

Effective communication and increased visibility throughout the organisation is a key part of the continuous improvement process. The ability to see a realistic, graphical representation of the work-in-progress, combined with live data collection and feedback is a huge benefit as it allows the company to plan ahead more efficiently. “Within the ETO cell the additional functionality within the finite capacity scheduling software that enables the cell leader to test different scenarios and highlight any capacity issues, means that it is possible to find windows of opportunity for essential prototype work. Seiki Systems has also allowed us to plan routine maintenance which, like most manufacturers, we had always tried to do. Now it can be scheduled in, we know that machine will not be available for two or three days and we can see what needs to be done to make sure we deliver on time. Seiki Systems allows us to plan and communicate efficiently in order to meet the demands of the customer. The next logical step will be to expand the full scheduling package out into the production workshop, one of Seiki Systems’ strengths as a solution provider is its ability to increase functionality as your needs grow.” concludes Neil Bennett.

Seiki Systems announces a partnership with Tricorn Systems that will extend the current job processing solutions offered by Tricorn by integrating with the full range of Seiki shop floor communications and machine monitoring software.

In the current economic climate, companies are increasingly under pressure to keep costs low whilst continuing to deliver value to customers, which means eliminating waste through the entire manufacturing process. The partnership between Seiki Systems and Tricorn Systems brings together complementary technology that will enable Tricorn’s manufacturing customers to utilise an integrated solution that links essential business processes to shop floor activities; streamlining the flow of information through the organisation.

The Tricorn Job Processing Software, introduced in 1987 and developed in the UK, includes a full suite of integrated modules that provide both management and operational tools, which are particularly suited to sub-contract, KOP, KanBan, made-for-stock and make-to-order manufacturing. Designed to improve the efficiency of the total manufacturing process through variance analysis, control of lead times, inventory and work in progress, the Tricorn solution will be enhanced by extending the process control and visibility out to the shop floor utilising Seiki’s complete shop floor system to electronically distribute and collect manufacturing process data.

Seiki Systems has over 20 years experience in the development and provision of real time manufacturing systems that provide live production management information and visibility to maintain a controlled and flexible approach to the manufacturing process. The company provides a scalable solution that will grow with the customers’ requirements. Seiki’s Networked Manufacturing System (NMS) comprises of both manufacturing and business intelligence software, which at the shop floor level includes features such as work queues, SFDC, machine monitoring, technical data distribution, DNC and probe data collection. The top office analytical suite offers a remote display of machine status, machine performance analysis and OEE, key business tools that are necessary for effective work management and to achieve maximum utilisation of critical production resources.

Seiki is hosting a series of free Scheduler workshops that will provide you with an opportunity to see a full product demonstration and discuss your requirements with one of our product specialists. If you are thinking of implementing a production scheduling system for the first time or looking to replace your existing scheduling solution, this workshop will provide an invaluable insight into what can be achieved with the Seiki Scheduler.

Dates:
Thursday, 24th September 2009, Tewkesbury
Thursday, 22nd October 2009, Brighton - Map to Brighton Offices
Thursday, 26th November 2009, Tewkesbury

Times: 10.00 - 12.30, light lunch and refreshments provided

For more information and to book call 01273 680411 or email sales@seikisystems.co.uk

Seiki Systems is delighted to announce that it will once again be exhibiting at the UK's premier manufacturing technologies show, organised by the MTA.

With just over a year to go before MACH 2010 the exhibition is already nearly 70% sold, an indicator that MACH is still fairly buoyant despite the current economic conditions, making MACH 2010 is the place to be if you want to see the latest in manufacturing technologies.

All the latest news about what Seiki will be exhibiting and how you can attend will be announced here, so keep checking back for updates.

Hall 5, Stand 5292

In the current economic climate can you afford to operate with inaccurate production information? Creating a leaner systematic approach to your manufacturing planning can result in significant capacity and efficiency improvements that can lead to real cost reductions.

Product Features

• Detailed capacity planning
• Appearance and functionality of a traditional planning board
• Simple drag and drop and "What-If" technology
• Set scheduling rules against individual operations

Product Benefits

• Identify untapped production capacity
• Reduce WIP and Inventory
• Achieve greater manufacturing flexibility
• Improve on-time delivery

We still have a few spaces available for our 7th July Scheduler workshop at our conference room in Brighton. The workshop provides you with an opportunity to see a full product demonstration and discuss your requirements with one of our product specialists. Book now to secure your place!

Date: Tuesday 7th July 2009
Time: 10.00am - 12.30 pm
Venue: Seiki Systems, Brighton - refreshments and a light lunch provided.

Following the introduction of lean manufacturing principles and the installation of powerful production scheduling software from Seiki Systems, railway electrification specialist, Brecknell Willis, has witnessed efficiency gains.

Based in Chard, Somerset, Brecknell Willis is one of the world’s leading suppliers of technology and equipment for railway electrification and for more than a century has been supplying equipment to rail operators across the globe. Initially the company manufactured overhead supply systems for trams and trolleybuses. However, today’s demands are far more diverse and include train borne systems such as pantographs and shoe gear, as well as fixed equipment which includes overhead trolley and contact wire systems. More recently it has moved into third (conductor) rail, and the company operates its own rail shop where it produces aluminium/stainless steel rail sections as well as the associated fixturing and brackets. 

Part of the Fandstan Electric Group, which has companies in North America, Australia and Europe, Brecknell Willis carries out all of its design and manufacturing at its extensive Chard facility. Many long running contracts and a large number of maintenance programmes are keeping the company busy. As production and material controller, Steve Crimp, explains: “Railways vary around the world and the reason why we have been successful is our ability to design and make bespoke systems for specific customers. For example, we are currently working on a large installation being built in Dubai.”

Developing next-level technologies as well as designing to match customer specifications, the company’s product expertise is evidenced by the fact that around 60 per cent of the 180 employees are directly involved in system and equipment design.

Both the train-borne equipment department and the electrification department (which looks after all fixed equipment) rely on the company’s machine shop for component parts, and it is Seiki Systems’ Networked Manufacturing System (NMS) and finite capacity scheduler modules that allow Steve Crimp to control the flow of parts through the machine shop. At present he uses the software for work planning of the machine shop, as Brecknell Willis has its own database system for stock control. The Seiki Systems integration software picks up all the parts from this database for both the rail and train-borne shops, and also controls the electrification parts that need to go through the machine shop.

There is a mix of new systems for customers as well as repair work, as Steve Crimp points out. “The amount of Brecknell Willis equipment out in the field means that about half of the work going through the machine shop at any one time is refurbishment and overhaul work. We are currently repairing and overhauling between 30 and 40 pantographs every month coming in from all the different train operators. These could either be damaged or just scheduled maintenance to ensure safe operation.”

Within the machine shop the company operates four twin-pallet horizontal and four vertical CNC machining centres, a manual turning/milling section with pillar drills, three CNC turning centres equipped with bar feeds and automated sawing machines that generate billets of raw material. It also houses a centreless grinding machine and a small boring machine as well as a router for composite machining.
 
The machines cut castings, billets and bar stock material as well as fabrications from the company’s assembly shop. For example, the cradle for shoe gear is a complex fabricated assembly that bolts to the underside of the train and is fed by an arm with a collect shoe on the end of it. “The collector shoe is a consumable item and we machine 1000s of them mainly, from cast iron but also copper for some systems. The shoes are machined, drilled and tapped in batches,” says Steve Crimp.

From his desk via the Seiki Systems software he can access live data from the shop floor. Terminals within the workshop allow the machine operators to log on and off jobs, with up to 1800 jobs loaded on the system at any one time. “Although currently there are just 900 jobs you still would not want to do this any other way,” he says.

The software provides graphical views of each machine loading and enables the operator to view a queue of the work due on the machine. Steve Crimp can manipulate this queue from his office, so rush orders can be dropped in and projects on longer delivery deadlines can be pushed back. Scheduling is vital for Brecknell Willis because space is at a premium as there is little room for further expansion on a site that has been occupied by Brecknell Willis since the 1930s.

All of the company’s forward orders are input into the scheduling system to provide a long-term capacity plan for the machine shop. “It is a really flexible and easy system to use,” he says. “Projects can be put on a delayed start if we have, for example, a problem with the material supply or if there is an engineering concession raised by the customer.”

Full visibility on screen of each machine on the shop floor means Steve Crimp simply rolls the mouse over the machine image to see exactly which job it is working on. Run over two shifts the manufacturing hours available each day are set by the machine shop manager. Any machine problems are compensated for by removing the hours available, in which case the software simply cascades the orders forward and re-adjusts the schedule. Steve Crimp says: “It will also highlight the change on the component screen, so I can see what the ramifications are. I can then make a decision to subcontract the work in order to hit the customer delivery timeframe if required.

One of the main benefits the Seiki Systems software has provided with its ability to accurately schedule work is eliminating the need to break down jobs. “Prior to installing Seiki Systems we were constantly fire-fighting and taking jobs off machines before the batch was finished,” Steve Crimp recalls. “Since installing the software we have not had to break a job down unless there is a shortage of raw material. We let the jobs run because the software gives us the ability to look ahead and forecast our production performance. It’s very visual and predictive, which allows us to act very quickly.”

Although the software has been installed at the company for two years, Steve Crimp recently attended a training session at Seiki Systems offices in Brighton. He says: “I had the initial training when the software was first installed and have been learning on the job. However, the refresher training has taught me a great deal more about what it can do.”

For example, he now uses the ‘set up marking’ function, which allows the user to pool together jobs that have similar machine set ups. These are typically families of parts, but they may be required by different customers. The software draws a line through each part in the schedule and allows the user to pull them together, thereby reducing the set up times required.

“Under our lean manufacturing principles we only make to order not for stock,” Steve Crimp explains. “So, we may require batches of the same part 20 times but for different orders. Using the set up marking significantly improves our efficiencies, and I’m really impressed by the difference that such an easy-to-use tool makes to the way we operate.”

For the management team it also provides performance measurement statistics for each job. “I can also see machine tool utilisation and quickly adjust any overload situations by moving work from one machine tool to another. Although the route card is set for a particular machine, I can move it from one resource queue to another within the Seiki Systems software and it will then alter what the operator sees on the shop floor,” he says.

Prior to installing the software everything was done manually on Excel spreadsheets with paper ‘work-to’ lists. Now individual operators can see an electronic work queue for their machine. Because the stores have the same view of the Seiki Systems software as production control, the company introduced work station job packs. These allow the stores to kit jobs with the cutting tools and raw material required to complete the job.

Steve Crimp also uses the software to monitor trends and to check the lead times on the machines. “There are seven solid weeks of work loaded on to the machines at present, he says, “but I’m trying to manage them down to six weeks so that our projects people can work on a known delivery time – for new projects or spares/overhaul work.”

He concludes: “We have the proof that Seiki Systems scheduling system works and we know the benefits. Now we are considering extending the scope of the scheduling software to include the fabrication shop and the assembly shop to provide better visibility. I will be able to see the progress of work that is due to come into the machine shop and they will be able to monitor the progress of the parts required for any fabrications. As we subcontract on an overload basis, if we know it’s going to happen we can control it.”

The new DLoG device adding to the family of 15” touch screen industrial computers is at the cutting edge of technology. Combining the advantages of a robust 15" touch screen industrial PC with the low TCO (total cost of ownership) of a classical thin client, the launch of the DLoG ITC 7 comes at just the right time, as demonstrated by high demand by customers as well as a positive response from systems integrators after market introduction.

DLoG GmbH has begun delivery of the "Industrial Thin Client", the DLoG ITC 7, which was announced last November at SPS/IPC/DRIVES 2008. That concept bundles the application-relevant features of a robust industrial PC into an overall system with the low TCO of a thin client. This allows DLoG to offer an optimum solution for the requirements of industrial and commercial customers.

DLoG ITC 7: for continuous reliable operation in harsh environments

The Intel® Celeron® M-based device series with a fanless design is protected to IP 54 against vibration, dirt, and water. With a break-proof 15" touch screen, it is designed for use in harsh environments. Specifically designed to manage the technical requirements for applications like data entry, visualisation, and communication in production and manufacturing, the DLoG ITC 7 thus combines a very attractive procurement price with mature DLoG product quality and high-quality service solutions for the lowest possible total cost of ownership.

Innovations in the housing design are also convincing: with a space-saving depth of only 70 millimeters, the DLoG ITC 7 permits simple access to interfaces that are protected via an easily accessible service lid. A service USB interface, which is protected by the service lid, for mass storage and input devices allows simple configuration and loading of updates. An integrated Compact Flash® slot ensures application-specific expandability. Besides mounting using RAM mount brackets, DLoG GmbH also offers separate individual mounting brackets in its comprehensive accessory range. These provide the 15" device with a secure mounting under a variety of conditions in stationary use.

"Many customers in manufacturing and production are looking for solutions in the current economic climate which are within their budgets whilst offering the performance they need, and simultaneously generating planning accuracy with a low TCO. In the DLoG ITC 7, we have come up with a new device class that is just what the market is looking for," reports Thorsten Kraus, Head of Business Development & Marketing (BDM) at DLoG GmbH. "The new device series has seen great demand since its introduction, and now full series production has started. The response from our sales partners and initial users of the 'slim' industrial PC is very positive," summarises Kraus.

With more than 100 years experience, ABS offers one of the most complete wastewater technology portfolios in the world. Divided into three business segments – domestic and commercial wastewater, wastewater collection networks and wastewater treatment - the company’s wastewater products have to compete in a global market. The efficient manufacture of these products is supported by Seiki Systems’ Networked Manufacturing System (NMS).

ABS Production has been operating for 35 years at its facilities in Wexford, Ireland, producing wastewater pumps for a global market. Approximately 250 people work at this site, with two thirds employed on the shop floor. A large research and development facility was opened three years ago where next generation products are designed and tested prior to launch, and larger existing products are life tested to failure.

Equipped with an extensive array of CNC machine tools the company’s workshop operates around-the-clock. The CNC machines are arranged as 12 manufacturing cells, with most cells containing a lathe and machining centre, as well as component washing plant. Operating a cellular system means that material flow is very efficient as all parts are completed within the cell. “For example,” says production support engineer, Sean Mahoney, “a main component like the cast iron motor housing is produced in a dedicated cell, while the oil chamber, which is also machined from cast iron, would be produced in another dedicated cell. This allows us to invest in the best machine tool technology to suit the part being produced.”

The cellular manufacturing method also allows one skilled operator to run all the machines within the cell to gain the maximum labour efficiency. Daily production meetings set the targets for the machine shop based on the global sales forecast by the company and works orders are issued to the cells.

Each operator has a PC in the cell running Seiki Systems’ Networked Manufacturing System (NMS) where all the NC programs required for that particular cell are stored.  Each program has associated operation notes, including tool types and positions, fixturing required and raw material.

The operator is also able to call down the part drawing via Seiki Systems software so that visual and dimensional checks can be made during set up. Sean Mahoney states: “This is a great aid to operators and gives them the confidence to produce the parts correctly.”

Any NC program changes are automatically logged via the NMS software so that engineering changes can be monitored and controlled. “Seiki Systems software ensures we have the correct revision drawing automatically available for each operation eliminating the risk of setting up and machining to an outdated drawing, which would waste production time and, in the worse case, scrap parts,” Sean Mahoney explains.

Updates are authorised in the engineering office so any changes, new drawings, or new components issued to the shop floor will be done through the company’s central server via Seiki Systems software, so the only version that will be available to the shop floor on the screen is the correct one.

Recent investment in the new impeller cell takes the engineering capability of the company to the next level, as parts are completed by just one multi-tasking machine tool. That said, there are two machines in the new cell and each is configured to suit a range of parts, controlled predominantly by the size of the finished component. The variety of impellers – there are 205 different impeller designs - require different jaws and back stops, so the cell operator can call up the setting drawing through the NMS software, which will contain a jaw and back stop number. Sean Mahoney has constructed a spreadsheet which is viewed by the operator through the Seiki Systems software. It contains details of the raw material type, the pump model it is fitted to, first and second operation jaw numbers, availability and storage positions for each of the first and second operation jaws, as well as the back stop required. The Seiki software also highlights if the component has been proven.

James Fletchmoore, director of JCNC, Seiki Systems agent in Ireland, says: “The Seiki software provides all the set up information. If it is a proven program it is literally a case of loading the jaws and back stops, setting the datum points and pressing cycle start, so efficiencies have been dramatically improved.”

Because the company works on a daily production basis to match order fluctuation the shop floor needs to be able to change from one part to another very quickly. Sean Mahoney recalls: “The production batches are very small and there could be eight different impellers going through the cell in a day. Before using the cellular manufacturing system a change over might have taken 1.5 to 2 hours by the time the operator retrieves the parts required from the tool store and the fixture store. Now everything is contained within the cell, including the prepared raw material blanks, and all the necessary data is available thanks to Seiki Systems. This is one of the reasons changeovers can now be completed within 30 minutes. Although, the part-to-part target with the new impeller cell is just 15 minutes.”

Pumps produced in Wexford cover a wide range of performance characteristics to suit various applications supported by ABS. The variety could easily lead to mistakes so the information available from Seiki Systems becomes a vital part of the quality assurance system. New product introduction is also a lot more efficient and will keep improving, as Sean Mahoney says: “Any new products designed are done with single machining operation in mind.”

As well as sending information to the shop floor the Seiki Systems Monitoring software is used to gather data on the machines’ performance, with relays wired into the machine’s controller to log run time, waiting and stoppages. From the engineering office Sean Mahoney can see a graphical plan view of the machine shop with the status of each machine shown in real-time.

He says: “Live data provides feedback from the shop floor with the machine tools shown in green if the machine is running in production, amber for a maintenance/waiting condition and red for switched off.” Periodic analysis can be carried out on each cell to show production time, down time and waiting time in a chart form for the management team, the actual Resource Utilisation.

“ABS Production has migrated away from a produce for stock operation towards a much more efficient make to order business but to achieve this it has needed to cut the changeover times and introduce the flexibility required to be able to efficiently produce a batch of one. Seiki Systems’ NMS has been fundamental in aiding this transition,” confirms James Fletchmoore.

www.absgroupireland.ie

Read the latest news from DLoG (UK) Ltd in Issue 1 of their Keep In Touch newsletter:
DLoG (UK) Ltd - Keep In Touch Newsletter - Issue One

Planning to Improve
Tuesday 10th March 2009

A recession forces you to make tough decisions and brings your attention back to the basics. Now is the time to vision new process relationships and revitalise older and traditional practices in the face of challenging economic conditions. 

Seiki software can be used to integrate and advance the disciplines across the manufacturing enterprise, creating a trusted factory knowledgebase where performance and quality can be achieved through control and continuity. Creating a leaner approach to the manufacturing process can result in significant visibility and efficiency improvements that ultimately provide the flexibility needed to react to any changing economic climate.

Becoming a more focused organisation now should ensure that you are better enabled to make best advantage of the opportunities that arise when we start to recover from the current recessionary crisis.

We would like to invite you to attend a joint seminar by Seiki Systems, GS Productivity Solutions and Renishaw plc that focuses on reducing your operating costs without a large investment in new equipment. The event is to be hosted by Renishaw at their New Mills site in Gloucestershire.

Agenda

10.00 - Arrival
10.15 - Cost effective ways to become more productive
10.20 - Ways to improve your machine tool productivity
11.00 - Coffee
11.45 - Seiki Systems and GSPS - Planning to Improve
12.15 - Lunch
13.00 - NEW Enhanced PC-based probing software
13.30 - Calibration products—allowing manufacturing industry to  control machine performance and achieve substantial cost savings
14.00 - Close/questions

Renishaw plc
New Mills
Wotton-under-Edge
Gloucestershire
GL12 8JR
Tel: +44 (0)1453 524524
Web: www.renishaw.com
To download directions via Renishaw website click here

Spaces are limited so be sure to register early. Visit the Renishaw website and complete the online registration form* or email marketing@seikisystems.co.uk. *

Please note that you will need to select this event from a drop down menu.