Leanworx production monitoring system provided the management a clear picture of downtime durations and reasons, and rejection quantities and reasons. On CNC machines there was drastic reduction in late starting and early stopping in the first month itself.

Leanworx production monitoring reports highlighted a number of problems. In the first couple of days it was found that the last 2 to 3 hours in the night shift showed zero production. This too resolved itself. Waiting for raw material was a common cause of downtime that as identified, focused upon and reduced. Rejections in a few CNC machines and in the mould making were high, and were reduced. Frequent breakdowns in some old CNC machines and in the air supply to core shooters were identified as key causes of reduction in availability.

Leanworx sent automatic alerts to personnel at various levels on their mobile phones – alerts for breakdowns, big downtimes, high rejections, etc. Immediate action was taken on such alerts.

Here are some of the reports in Leanworx production monitoring system that the firm used to achieve the transformation.

Firm and machine names have been changed to protect the identity of the firm.