Obeikan Folding Carton (OFC) lacked visibility into operations and assets. They were unable to identify challenges in real time, resulting in OEE losses, multiple shifts and poor rough cut capacity planning.
OFC struggled to adapt to changes in schedules, products and were unable to manage rapid changeovers to support high mix manufacturing. The excessive operator manual data entry impacted productivity.
ODS reviewed the current IT landscape at OFC – which encompassed several systems and
deployed GE Digital’s Manufacturing Execution System along with its suite of plant applications
to enable the following functionality:
- Provide accurate status and picture of ongoing manufacturing operations, OEE tracking for transparency of operations
- Monitor and control asset use to minimize operating costs
- Integrate legacy systems with the enterprise and accommodate heterogeneous systems
- Improve planning and forecast inventory timeously
- Real time operational intelligence with end-to-end traceability and product genealogy
- • Refine and digitalize SOPs
The adoption of O3 along with its plant applications has helped OFC at all levels – from operators to plant managers to GMs. The insights and the real time visibility provided by the solution has
delivered the following benefits:
- Improved OEE by 11.1%
- Reduced unplanned downtime by 12%
- Decreased Customer Complaint Records (CCRs) by 80%
- • Optimized job scheduling
- • Lowered costs by 10%
- Provided detailed insights on Mean Time to Repair (MTTR) & Mean Time between Failures (MTBF) to improve maintenance practices