December 2015 – KSC Global Solutions

KSC Global Solutions supports IOT strategy worldwide

A typical manufacturer spends millions of dollars on equipment each year — 10 percent (median) of plant sales — yet many fail to optimize the performance of those investments.

That’s why leading executives focus on incorporating those assets into a Connected Enterprise framework — one that allows them to see how equipment operates in real time (product variance, energy draw, machine reliability, maintenance requirements, etc.) and to proactively address potential problems before they impact production. This leads to production improvements (quality, costs, delivery, safety), longer equipment lifecycles, and improved profitability.

How big is the opportunity in asset management? The machine availability rate for manufacturing plants is 87.5 percent (median) as a percentage of scheduled uptime — a typical operation can’t run machines one out of eight times they’re scheduled. For many manufacturers, the downtime is much worse: 30 percent of plants report machine availability of 75 percent — machines aren’t available one out of four times.

These numbers reflect millions of dollars in lost productivity for plants from equipment failures, which doesn’t include millions more from related excessive energy consumption and/or poor quality when equipment fails and restarts. Those figures show up in overall equipment effectiveness (OEE) — a measure of machine reliability, quality yield, and capacity to produce — which is 80 percent (median) at plants, leaving room for major improvements.

Given these asset-management numbers, it’s not surprising that 10 percent (median) of plant maintenance costs are unplanned.  In a Connected Enterprise, however, maintenance becomes proactive as warnings signals from equipment and embedded devices are communicated before machines stop.

Even more valuable is how real-time data can influence operations in real time. In a recent implementation, a cosmetics manufacturer installed the Rockwell Automation FactoryTalk® Metrics software, which generates accurate reporting of real plant-floor activity.

Executives used the software and intelligent devices to monitor, collect, and analyze production data while equipment ran, and were able to dramatically improve OEE and quality of a line previously plagued by downtime. Engineers at this facility now perform PDCA (plan/do/check/adjust) on the fly: they identified problem areas and then configured FactoryTalk to calculate and visualize future OEE for the monitored equipment. When operators receive an alarm, they quickly find the root cause of the stoppage and access the required data for solutions.

The Connected Enterprise also provides information on an enterprise-wide basis that can predict future asset requirements based on energy-consumption, quality trends, maintenance histories, etc. Combining equipment data with demand projections, manufacturing engineers can specify next-generation equipment. For R&D departments, this data allows design engineers to create products that are easier to prototype and manufacture.

The Connected Enterprise offers increased profits now and competitive differentiation tomorrow. Why is your company still stuck in yesterday’s asset-management?

UK Manufacturer heads Sustainable Innovation

Genesis Biosciences wins Major UK Sustainability Product Innovation

2nd November 2015By Genesis BiosciencesPress Release

Welsh biosciences company Genesis Biosciences has won a major UK sustainability award for an innovative new cleaning product which uses microbe bacteria instead of traditional chemicals.

Genesis won the ‘Sustainability Product Innovation’ category at edie’s 2015 Sustainability Leaders Awards for its development of ‘Evogen’.

Evogen radically changes the way we think about cleaning.

Judges described Evogen as an extremely exciting and innovative product, with massive potential.

Primary Judge and Head of Programme at RSA Great Recovery Lucy Chamberlain said: “Evogen radically changes the way we think about cleaning; about the environment and about our responsibility to use a more effective, lower cost, ‘friendly’ alternative to chemical cleaners”.

Speaking after being presented with the company’s award in the ceremony in London, managing director John Clark said: “Winning this award is the culmination of extensive research into application-specific bacteria which has resulted in unrivalled results across a series of markets.

“The whole concept of the Evogen range is to provide the lowest environmental impact product to every cleaning solution. We have made giant strides in the facilities management, marine and waste water treatments markets and are extending the applications to many other sectors globally.

“This recognition is well deserved by the small and dedicated teams here in Cardiff and across the ocean in our Lawrenceville manufacturing facility and we were delighted to receive the honour”.

After a record-breaking year of entries, 88 finalists were whittled down to 14 separate winners, with categories ranging from Energy and Water Management through to Sustainable Supply Chains, Employee Engagement and Product Innovation