Plug. Measure.
Act. Improve.

The good thing about it is we have a big monitoring system on the shop floor with all of the data being captured, so we can catch it every 2 or 3 minutes. Then Leanworx itself sends an email out after each first shift, which is determined by the user. And then you can review that with the management team. You can present that in terms of what's running good, what's running bad, what needs improvement, and then you can look, you can take a deep dive on the steps - why it's not working well at the moment. With Leanworx, we've kind of tailored a dashboard just to give us the information which we require. So we're monitoring spindle utilization. We have been using Leanworx for about three months now, and we've seen significant improvements in terms of our cycle time, our understanding of the spindle utilization. We've seen a lot of OEE improvements because now we can understand the parts, the spindle runtime, how effectively we are running. It's actually helped us to move from 3 shifts down to 2 shifts with more output. So we've moved from about 30% spindle utilization to now over 55% spindle utilization. It's allowed us to put a bonus structure in place which is monitorable.

We've been extremely happy with the way that they've worked, which is coming from the way that the utilization of the machines has improved. Our downtime has decreased by 10%. The downtime, especially in the night shift, has reduced by more than 25%, which is a very, very important thing for us and is contributing a lot towards our productivity. So I would definitely recommend Leanworxs to others who are doing CNC machining like we are. We are spread over four plants, but can control them all from our office, looking at the data, getting information real time, getting updates and reports every day. It keeps us extremely well connected, very much in control, and able to see what the utilization is at any given point in time. So I would highly recommend Leanworx to others.

Overall, I see at least 8 to 10% efficiency improvement, especially OEE and the spindle run time. Spindle run time is effective utilization of spindle. There were a lot of idle times. Setup time has been reduced. We can see an improvement of at least 10 to 12% production improvement. Just put in a monitoring system, then the discipline came into picture. Further details came out and we identified the root causes, improved the efficiency. That's how we have implemented, thanks to Leanworx. There is good support, good teamwork and it's affordable.

We were satisfied with the results, the part count accuracy. So we installed it on 100 machines. We installed Leanworx on all kinds of machines like CNC turning centers, VMC, grinding machines, honing machines, leak testing machines. And we were very happy with the ease of connecting Leanworx. It takes hardly 10 minutes for a person to connect to the machine. I can tell you that we are able to reduce the downtime, we are able to improve the productivity. The middle level supervisors and managers are also satisfied with the exact data that they are getting from the Leanworx system. The reports are also quite user friendly.

With Leanworx we have been able to bring down our machine downtime by about 30% and increase in OEE by 10 to 15%, which is a huge saving. Now we plan to connect all the 24 machines we have through Leanworx and get comprehensive data on that. We have been getting fantastic results out of it. The reports that we generate every morning give us a good insight on the productivity and the performance of the operator as well as the machine. I recommend it highly to all the manufacturers who have CNC setups or any machines that can be fitted with this.

Sanjay Desai

L Krishnan

The quality of data, accuracy of data, timeliness of the data is very, very important. That's how Leanworx is helping. After implementing Leanworx we are no longer discussing the quality of data or accuracy of data. Discussion revolves around what can be done to improve the productivity. Looking at the benefit of utilizing and improving the equipment utilization, the incremental cost that we incur by paying the subscription is very small and it's a good value proposition from our point of view.

Anil Machani

Like earlier, what we used to assume is, we used to trust our operators for any data which is not in line with my actual calculations. The big gap, which we have been cleared off now. So I get a real data right from the machine. So the efficiency point of view earlier, like OEE, we used to say customer, when customer asks, what is your OEE? We say 85%. Are we really at 85%? I don't think so. We know in reality, with the downtime, what we have undocumented downtimes or any other material waiting period. These are all not documented. So this can never. When our one end example, what we saw was it was not crossing beyond 56%, whereas we have been declaring, so the gap is too big. So that got now, after installing this particular IoT, getting into the IoT that materialized into actual usable time, We are pretty close to actual of 85%. In fact, it's 88 when we finally checked the last time. So that's a substantial advantage. What we get or benefit what we get through IoT.