Challenge
Following an introduction to the LCR4.0 Holistic team at Liverpool John Moores University (LJMU) a consultative support process via a combination of digital diagnostics and readiness level assessment which resulted in a range of support opportunities centring on high-value steel cutting processes to improve productivity, energy efficiency, environmental impact and customer services levels.
Solution
HTSS took advantage of the improvement opportunities which resulted in agreeing to support a digital demonstrator project to digitalise a flat sheet metal blanking line. LCR 4.0 Holistic designed, resourced and managed the digital demonstrator project with added support from external accelerator partners providing hardware integrator and remote access software & data storage/display expertise.
Our partnership with LCR4.0 Holistic has been a real eye-opener and has given us the means to increase our factory efficiency and also save costs.
I would recommend anyone in manufacturing to take advantage of what it has to offer.
Ian Gorman, Managing Director of Hi-Tech Steel Services
Impact
The enhanced on-site digital capability captured critical operational data which was feedback in real-time to the management team via a dashboard giving insights into line utilisation, electrical energy consumption costs and environmental carbon footprint impact.
The demonstrator was able to quantify the blanking line non-production time which has already identified line utilisation improvements via better job order planning, sequencing and minimising set-up time, resulting in an additional 2842 metres of flat sheet steel processed per week ( effectively an extra coil per day ), using 10 % less energy & carbon foot print.
The support provided by LCR 4.0 Holistic has helped to digitalise & monetise the blanking line facilitating more informed shop floor and management team decisions which ultimately improve productivity, customer service levels and profitability. HTSS will now put a plan in place to commercialise the digital demonstrator via a permanent installation focussing on the quick win areas to minimise payback time and maximise return on investment.
