full-service solution , the Red Lion team provided the production department with the functionality and features that enabled accurate production data on demand . With agnostic hardware , easy to understand visualization formats , and remote monitoring of data , Red Lion solved the customer ’ s challenges effectively . Kaleesuwari was excited about the comprehensive PLC connectivity provided by the PTV , regardless of the many differing PLC brands or types currently in place on the shop floor , along with multi-protocol options .
Since the implementation , Kaleesuwari has experienced many positive results . Automatic time logging with production data is helping the company understand the performance and capacity of each machine . To date , they have experienced an 8 % improvement in machine output per line . However , they continue to finetune the process in order to gain further efficiencies from their production lines .
RESULTS
Featuring an HMI dropdown box that lists possible reasons for a machine failure , operators simply click on the appropriate pre-programmed explanation . Management is immediately notified when a breakdown occurs , the basis for the problem , as well as contextual data for the machine , helping the company to better understand root causes and track recurring issues . Within the first 4 months , Kaleesuwari reported a 40 hours cost saving in machine downtime .
Collecting production and downtime data from 24 machines , all Delta PLCs and HMIs are connected with PTVs and synced to PTV screens , allowing for remote monitoring . Kaleesuwari now has access to real-time data for raw input , packet production , oil loss , and total production output , leading to overall plant performance improvements . As a result , errors in bag counts have significantly decreased . With data accessed directly from the machine on packaging bags used , the company has experienced a 15 % reduction in bag waste per line .
The improvements that Kaleesuwari has seen with the help of Red Lion solutions have led to an increase in manpower efficiencies in other areas of the plant . Providing indispensable data that can help the company achieve increases in revenue and customer retention , these successes have led to discussions for further installations within the plant . With approximately 16 lines in total , the customer plans to install Red Lion ’ s innovative streamlining solution on at least four additional lines by the end of the first quarter 2019 .
While more data collection is needed to determine the impact on sales , the implementation of the Red Lion solution has opened up the opportunity for Kaleesuwari to utilize other products within the company and implement cloud-based solutions for all six of their plants . The company feels certain that , as more dedicated Red Lion systems are implemented , a true measurement of overall business impact and value will be ascertained . Today , Red Lion continues to work with Kaleesuwari for predictive maintenance and data visualization solutions .
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