Automation

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Project Manager

Project Length

  •  3 Months

 

Objective

  • To complete 3 Projects on time

  

Issues to start with

  • Projects running late

  • Experienced Project manager had left the business

 

Plan to fix it

  • Project-managed a refurbishment/ re-tooling of two machines used for assembling rear metal scuff plates on X761 for JLR via GSM.

  • Oversaw the implementation of three new fixtures for Plastic Omnium, to do the Ultrasonic Welding on Bumpers for JLR.

  • Supported the management of a conveyor fill line build for Bushmills, midway through the project.

 

Issues on the way

  •  Continued adjustments to plan to match resource and materials availability in real time.

 

Result

  •  All 3 projects delivered on time

Machine Retrofit

Project Length

  •  6 Months

 

Objective

  •  Reduce downtime on critical path slitting machine (Durmec).

 

Issues to start with

  • Machine was made up of old sections from different machines.

  • Hard wired control system was out of date.

  • Electrical spares were not available

  • Repairs relied heavily on the person who originally put the system together

  • Hydraulic System had been neglected.

 

Plan to fix it

  • Install new control system for machine

  • Carry out a full review service and upgrade of hydraulic system

  • Complete a capex for £70K of capital expenditure

  • Plan stock build to enable final installation and commissioning in 2 weeks

  • Identify maintenance plan and implemented regularly

  • Re-train employees

  • Monitor issues and review daily for Corrective actions

  •  

Issues on the way

  • Continued downtime issues eroding safety stock.

  • Upskilling of employees for touch screen and Can Bus technology.

 

Result

  • Control System was installed and commissioned in a 2 week window over Christmas

  • Hydraulic system re-furbished

  • Downtime due to breakdown reduced to less then 1%

  • No disruption to customers commitments

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