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.”

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

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.