We are seeking a motivated and enthusiastic individual to be responsible for the implementation of our ERP and Scheduling solutions for our customers, ensuring a high degree of customer satisfaction in our products and services.

Production at hydraulic valve specialist Integrated Hydraulics is strictly ‘due-date’ led with output geared to meet order targets.  Before the installation of Seiki Systems’ iMES scheduling system, the process of  tracking down where a job was on the shopfloor used to take an average 30 minutes of precious management time followed by questions being asked to determine which operations had been completed and the estimated time for the batch to be finished.  Worse still, this often led to countless additional time spent debating the type of actions to be taken in order to respond to changing customer requirements. 

Outlined Tony Cave, senior production engineer:  “Following the installation in September 2006 of the Seiki Systems iMES scheduling system, which was fully integrated with our Sage Line 500 MRP system and the existing Seiki Systems Networked Manufacturing System (NMS), the internal phones have almost stopped ringing as people requiring production information now have live terminal access to the exact state of play.   Thanks to iMES, my team can now get on with their jobs,” he said.

Integrated Hydraulics is a £27 million business producing over 500 types of hydraulic manifold bodies for its range of screw-in cartridge valves and systems.  These are exported to 20 countries from the 28,000 ft2 Warwick factory to customers in the off-road, agriculture, earth moving, mining and construction sectors.  Most machining is carried out in-house on the three C Dugard-supplied Hyundai-Kia V50D vertical machining centres installed this year, Hitachi-Seiki horizontal machining centres and semi-automatic, special-purpose, six-spindle turret machines.

Most production schedules involve some 350 different jobs with around 22 new jobs loaded daily.  Each morning at 7 am the server for Seiki Systems iMES scans the MRP system for new orders and repeats its cycle 12 hours later in order to assemble the new business into a passive job queue. The Seiki Systems iMES then interfaces with the NMS software to update the job queue from activities and, behind the scenes, checks the activities carried out over the previous 12 hour period, then automatically re-plans the workload on the shopfloor. All new jobs are allocated according to production engineering layouts to individual machines based on delivery date and the iMES software checks for material, tooling and program availability and immediately flags an order requirement to the supervisor if details are missing or if there is a warning of a possible problem. Should the first choice machine be overloaded in terms of capacity, the system then informs supervision of viable options, depicts the second choice route and outlines its viability.  If program and tooling are available it will then import the relevant information.  Then, according to the scheduled start date to meet the delivery target, a list of tooling requirements is automatically transmitted to the tool stores ready for kit marshal and machine setting.

Through iMES, which has terminals in all key departments, and beside each machine tool, a colour coded screen planning board for each machine communicates current production information in a bar presentation format over the 24 production hours available each day, and creates the actual and future machine loading.  Holidays, planned maintenance and setting time are included and any changes that influence the flow of work, such as inspection stoppage or breakdown, are immediately identified to provide a warning and live update of any roll-on effect of the scheduled work in the form of delays.  Through a time view screen, decisions can be made from showing the roll-on effects of jobs being moved or batches split between machines in order to recover a situation with instant feedback on effects to existing works orders being processed.  The software uses a traffic light system to quickly identify the progress of each job: green depicts due day target OK, a light green warns that the job will be a close call with yellow used for ‘just in time’.  Once the screen changes to orange, delivery is one week behind and red shows some serious remedial action will be required to bring work back on track.

Back on the shopfloor operator co-operation is paramount to which Tony Cave adds:  “Everyone can see the benefit of iMES and the operator simply ticks the appropriate route card on the screen when the job is started, if there is a hitch or delay, or the run is completed.  Because tools, program and material are prepared prior to setting on the machine, waiting time is limited and through the iMES queuing system, it lets the operator know what is on the agenda and the urgency.” The previous planning board system was based on a single resource of CNC machines and could not track other processes such as deburring, washing etc to show a completed process log of the part.  As a result, there was limited information available once work was in progress.  And as Tony Cave describes, everyone used the telephone, or worse still, emails flew around the company requesting information. Data was input manually and any immediate problems were satisfied with the work being shuffled to try to meet targets.  However, this had little regard to longer term repercussions and resulted in the moving of problems further down the line. Today, anyone who needs to know can see, within one minute (the routine scanned update cycle from NMS to iMES) the exact state of production and even the sales team has the facility to check online to know exactly where any customer order fits into the ‘due-date’ schedule. In his production engineering role Tony Cave now has a fast track update, not only for program requirements and tooling problems but information on machine and process reliability.  And rather than rely on ‘gut feel’ that additional capacity or a replacement machine is required and the changes in work loading, he has factual information to initiate special attention, justify a purchase, or seek additional capacity through subcontract. Indeed, it was through iMES that the first Hyundai-Kia V50D was justified and once installed, such was its performance and high level of utilisation recorded by NMS, that two further machines were ordered from C Dugard.

On a weekly basis iMES sends an electronic delivery report to management giving an update of ‘due date’ situations and operations waiting to be completed. The weekly report is created to cover overall production and each machine showing production, alarms, maintenance, programming, waiting setting and housekeeping with at-a-glance pie chart breakdown. In addition, the full integration of NMS to iMES provides the vital link to traceability due to its factual reporting system.  Integrated Hydraulics knows the CNC program used on any job when it is returned from the machine via DNC where it is then compared to the original download to check any changes made.  The old program is then archived if approved by production engineering or an investigation carried out should there be a problem envisaged from any changes made on the shopfloor.  Tony Cave puts great store by the availability of the electronic diary that is a compendium of notes of operator actions, thoughts or comments and any problems or changes that are now archived with each job for reference on future batch runs. Also, records are made of production and quality data, original planned times and costs that are laid out against actual production achievement data.  Information is also recorded on machine history, materials and tooling to which Tony Cave adds:   “Used properly this is very important because no one will remember what happened even just a few days ago.”

Tony Cave’s development of the system is still progressing and here the modularity of iMES is able to support the growth and development of companies.  For Integrated Hydraulics the next stage is to build into the system subcontract operations to track, record and monitor the processes in the same way as internal production is recorded.   As a result, important information will be provided for management decisions either to put uneconomic tasks outside, or draw back in-house operations that need tighter control.

Read more about the Seiki Scheduler

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Our partners in the USA, JobPack Inc will be exhibiting at the South-TEC Show (IMTS) from 02 - 04 October 2007, followed by the Canadian Manufacturing Technology Show from the 15th-18th October.

South-TEC
The event promises to be the biggest yet featuring 90,000 square feet, 330 exhibits and a full technical conference. It will also feature Manufacturing for Performance exhibits geared towards motorsport manufacturers.

Exhibition details:-
Dates 02-04 October 2007
Venue Charlotte Convention Center, Charlotte, North Carolina, USA
For further details about the event, including pre registering, reasons to attend and a full list of exhibitors please visit the South-TEC website www.sme.org and follow the link from the Events and Expositions tab.

Canadian Manufacturing Technology Show
The Canadian Manufacturing Technology Show is the definitive exhibition of machine tools, automation technologies, production methods, management strategies and more. Places are limited so be sure to reserve your place early.

Exhibition details:-
Dates 15-18 October 2007
Venue Direct Energy Center, Toronto, Ontario
For further details about the event, including pre registering, reasons to attend and a full list of exhibitors please visit the CMTS website www.cmts.ca

Registration has now opened for MACH 2008. With floor space already sold out this promises to be one of the biggest and best MACH shows so far. Make sure to plan your visit early and register now via their website www.mach2008.com

Seiki Systems will be exhibiting in Hall 5, Stand 5151.

Our German partners Fauser-AG will be exhibiting at EMO Hannover and Seiki Systems will be joining them on the stand to demonstrate our shopfloor systems.

Make sure you visit us on stand F18 in Hall 6

Don't forget to add these dates to your diary!

As part of our drive to improve our overall business Seiki Systems are delighted to advise that we have appointed JCNC Ltd as our exclusive distributor for Ireland.

JCNC Ltd  is a new company set up by James Fletchmore who has extensive experience of Machine Tool sales, applications and support together with comprehensive knowledge of the Irish manufacturing industry. James will be offering the complete range of products offered by Seiki Systems and we look forward to his future success in Ireland.

If you are based in Ireland and would like to discuss any of Seiki Systems products then please contact James directly on: Tel: +353 (0)45 438272   Fax: +353 (0)45 438272

Due to the strong interest in our upcoming Performance Workshop the morning session is now full and only a handful of spaces remain for the afternoon session. Please contact Jamie (tel: 01273 680411) now to secure your place at the free workshop on the 12th July. As an additional benefit we have now also included an optional tour of the Renishaw Stonehouse facility for all those registered to attend the afternoon session.

If you are unable to attend on the day but would like information pack please email marketing@seikisystems.co.uk, please also indicate if you would like to be notified as soon as the date for the next workshop is confirmed.

Delivery
Quality
Profitability

Control production to meet delivery dates
Control the process to prove quality standards
Control costs to enhance profitability

To survive in the competitive environment of modern manufacturing it is essential to have integrated solutions that can enable you to manage your production simply and with confidence. Just as important is implementing tools and systems that will enhance your business; supporting the way that you work and allowing you to benefit from productivity improvements. Together we aim to help you to identify ways in which you can take control.

This will be a joint presentation by Seiki Systems, GS Productivity Solutions and Renishaw. There will be two sessions on the day:

Morning session 9.30 to 12.15
Afternoon session 13.00 to 15.30
(please indicate which session you will be attending when you register)

An optional visit to the Renishaw Stonehouse facility will take place in the afternoon for all those registered to attend the morning session. Again you will be asked to register your intention to take part in this visit on the registration form. Lunch will be provided between 12.15 and 13.00 for both morning and afternoon attendees.

Agenda for each session

Introduction
Production management and process control
Practical demonstrations & refreshments
Probing on a machine tool - Get it right!
Manufacturing intelligence and performance measurement

This is a great opportunity to discuss with our specialists ways in which your company can take control of the key issues of meeting delivery requirements, quality performance and enhancing profitability.

Venue:            Renishaw plc
                        New Mills
                        Wotton-Under-Edge
                        Gloucestershire
                        GL21 8JR

Date:               12 July 2007

Time:               9.30 – 12.15 or 13.00 to 15.30

If you would like to attend please click here to register. Alternatively telephone 01273 602564 or email to: jamiew@seikisystems.co.uk. There are a limited number of spaces available so be sure to book early.

Contacts

Seiki Systems Ltd
Tel: 01273 680411
Email: sales@seikisystems.co.uk
Web: www.seikisystems.co.uk

GS Productivity Solutions
Tel: 01454 261500
Email: info@gspsltd.co.uk
Web: www.gspsltd.co.uk

Renishaw plc
Tel: 01453 524524
Email: uk@renishaw.com
Web: www.renishaw.com

Seiki Systems NC Program Manager is an entry level system, comprising of a powerful text editor for creation and editing of NC programs, together with configurable communications to enable DNC transfer between the CNC machine and a desktop or laptop PC.

It has been specifically developed to meet the needs for creation, management, editing and transfer of NC part programs, all in a Windows® environment. The software uses the standard Microsoft Windows Explorer® for management and file selection which has the additional benefit of eliminating the need to continuously type the required field names. NC Program Manager is ideal for small machine shops or for use as a back-up system. Visit our NC Program Manager page for more information and instructions for downloading the software.

Congratulations to Kenard Engineering who came highly commended in the Best ROI measures and benefits from IT in Plant and Factory Improvement category in the Manufacturing Computer Solutions Best of British Manufacturing Awards 2007. It has been the installation of the totally integrated manufacturing system iMES from Seiki Systems that has enabled the company to control work flow and respond to customers, reduce work in progress and make the best use of the production resource of 15 CNC machines.

The awards are designed to recognise efforts for manufacturing and engineering business excellence through the use of good IT intelligently implemented and for achievements in terms of hard, measurable ROI and business benefits.

www.bestofbritishmfg.co.uk

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Congratulations to Brian Trill who made it back safely from his trip to Peru.

Brian, our technical support engineer who is a keen cyclist, took on the Macmillan Peru Cycling Challenge. As many people will already know Brian was unable to take part in the 7 day trek last October as he sustained a broken leg just a week before he was due to fly out to Peru.
Now completely healed and back on his bike Brian flew out to take part in the challenge that starts at Lake Titicaca (the highest lake in the world) across remote altiplano and past snow capped mountains before finishing at Macchu Picchu—the famous ‘Lost City of the Incas’. This cycling challenge is to help ensure that Macmillan are able to continue to support cancer patients and their families.

If you would like to know more about the Macmillan cycling challenge and how you can support the cause visit their website: www.macmillan.org.uk

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Our partners in the USA, JobPack Inc will be demonstrating at the EASTEC Show (IMTS) from 22 - 24 May 2007. For 28 years EASTEC has been the premier manufacturing event in the Northeast of America.

Exhibition details:-
Dates 22 - 24 May 2007
Venue W Springfield, MA USA

For further details about the event, including pre registering, reasons to attend and a full list of exhibitors please visit the EASTEC website www.sme.org/eastec There is a section dedicated to International visitors with useful contact numbers and advice on where to stay in the area.

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Using a combination of the latest Internet technology and telephone conferencing, Seiki Systems is now able to carry out live demonstrations and presentations of its manufacturing software solutions direct from its Brighton headquarters.   By using remote links and two-way discussions, the requirements and working practices of the customer can be immediately incorporated into the Seiki Systems demonstration of the features available in its software for evaluation. 

Seiki Systems is a registered user of GoToMeetingTM that enables live demonstrations and presentations to be conducted or support provided to customers over a secure Internet connection.  This easy to use online meeting and support facility provides a greater degree of flexibility and convenience.

As general manager David Trowell describes: “With the special website access and discussions using conference calling we can talk to almost any country in the world, involve people in other customer departments or sites as well as calling upon our specialists to contribute whenever required.  This has already proven very beneficial in two recent projects in Canada and Jordan saving the costs and distractions of long distance travel to make presentations and adjustments to our proposals right up to the point of offers being accepted in principle.”

Seiki Systems developed the presentation technique with its partner in America where it is often inconvenient and impractical to gather all the participants in a single meeting.  In particular, Internet conferencing is proving very successful in effectively demonstrating its Networked Manufacturing and iMES scheduling software packages because it enables a customised presentation to be shown with graphical simulation of the customers’ workload for the machine tools that are available.  In addition, pertinent factors can be added to show the effectiveness of the software to handle any consequences of deliberate or unforeseen changes.

Says David Trowell: “This capability now also enables us to provide a major benefit to our customers by providing technical assistance almost immediately as our support engineers are able to remotely log onto a customer’s PC and provide advice, diagnose problems or help with changes.   Customers have responded by saying they appreciate this level of interactivity, while each party has the convenience of familiar working territory.  In particular, this is seen as an important benefit when dealing with complex technical issues that would be difficult to diagnose and resolve over the telephone,” he maintains.

Visit our support homepage

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Exo-View is a specialised software package developed specifically to enable component suppliers to integrate with Exostar, the system used by aerospace and aero-engine manufacturers to inform their subcontract suppliers of delivery requirements.

Exostar is an ideal solution to enable suppliers to forward plan but due to the large quantity of information and with no method of highlighting any changes simply and quickly, maintaining the system can be problematical.

Managing Exostar schedules normally requires a dedicated member of staff, usually a senior manager, to spend many hours each week to manually run through multiple spreadsheet pages, often containing hundreds of lines, to check for any changes from previous issues. The implications of error can be serious as they can cause production and delivery problems not only on site but also for the end user.

As the principal requests that the supplier confirm that they can comply to these changes or notify of any problems with quantities, prices or delivery dates by the end of the week it is essential that the information you have is up-to-date. This means co-ordinating the latest Exostar release with your production schedules, which when done on multiple spreadsheets and using paper based methods can be time consuming and often inaccurate.

Exo-View, the latest product release from Seiki Systems can automatically analyse the customer's requirements quickly and highlight any changes, a task that normally takes days when done manually. A traffic light system also alerts to any items needing immediate attention. Further to this the system is integrated to the Real Time Scheduler allowing you to view the exact position and status of W.I.P, obtain an immediate forecast of any possible late deliveries and longer term effects on production.

An article featuring Exo-View ran in the latest edition of Aerospace Manufacturing. To read this article you can either download the pdf here or visit their website www.aero-mag.com.

If you are interested in learning more about this product contact us now to speak to your area manager. Email sales@seikisystems.co.uk

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