Poling Group News   |   Volume 5  |   Issue 2
Poling Group Factory Information Software
Are you a mid sized tire company?  Do you want to have plant information that flows like the largest tire companies?  Then start here

Large, multinational tire producers faced with the challenge of achieving productivity gains while improving quality, have historically responded with huge investments in manufacturing and material handling automation, along with the purchase and implementation of costly IT systems (along with their corresponding upgrade and training costs). Investments and costs of this type are extremely challenging to growing midsize tire companies who are already scrambling to obtain and deploy resources to meet current production requirements.
 
Since 1982, Poling Group company CTI has worked closely with global tire producers to acquire, store, and report tire data. We’ve witnessed the productivity and quality improvements that come from turning data produced by people and machines, throughout the manufacturing process, into actionable information. We’d like to use that knowledge base to suggest some ways in which midsize tire producers can leverage tire factory data to meet ongoing and future operational challenges – in a scalable, cost-effective way.

Product identification
 
Product identification yields the quickest results that have the highest impact on productivity and quality improvement. You can identify packaged or singular product with a bar code label or RFID tag to:

• Enable intelligent material handling. Regardless of whether or not you automate the process, delivering the correct product to a process set up to handle it is a crucial quality goal.
• Provide the necessary element for product traceability required by many OE customers and governmental agencies.
• Improve response to customer and product quality issues. Using product identification to track products as they are produced, moved, tested, and consumed reduces waste and facilitates future inventory management initiatives.

For some tire producers, the question is not whether to implement product identification, it is where to begin. Here are some places to consider:

Component Production: Start here to provide maximum finished product traceability and the most cost savings in scrap reduction.

Tire Building: Start here to verify product in the curing department and implement advanced analysis related to tire construction issues.

Curing Department: Start here and your material handling system can route tires to specific processes and machines in the final finish area. You can also track finished tire irregularities to a specific press or mold.

Capturing factory data
 
From production accounting to SPC monitoring, tire factory data collection plays a key role in improving productivity. The Poling Group knows how to collect data from machines and effectively implement web-based reporting for all your users – from operators to CEOs.

Users can customise and automatically schedule a variety of tabular, graphic, and dynamic Final Finish Host (FFH) reports.

TFFIS (Tire Factory Floor Information System), first installed in 1994, provides a customizable base for collecting and monitoring production statistics from each area of the plant. It can also generate automatic text message alerts to mobile devices, deliver accurate reports of production against designed objectives, and move actionable data from the production floor to plant and corporate data centers.
 

TFFIS delivers delay reporting
Use these reports to identify critical or frequent sources of downtime.
TFFIS delivers better floor communication
• Alert supervisors or maintenance 
   about unexpected production delays
• Call for stock directly from a product 
   bill of materials
 
TFFIS delivers delay alerts to cell phones, pagers, or email addresses.
TFFIS can monitor production cycles to deliver quality alerts
• TFFIS looks for variance related to 
   production sequence or time
 
• When interfaced to the machine PLC,
   TFFIS can send a quality alert, or if 
   the variance is severe, immediately 
   stop out-of-spec machine to prevent
   further production (and waste)

FFH (Final Finish Host) collects tire testing statistics from a variety of machines. When we encounter a machine without an existing interface, we evaluate it and provide a spec to the machine vendor to simplify the data acquisition process. We developed FFH specifically for tire manufacturing final finish to provide the data and reporting you need to satisfy both external and internal customers. Once communications are established, FFH can also automatically download auditable recipe information from a centralized location.

FFH has been customized for and successfully implemented at several global tire companies.

• Provides a single access point to control customer specs, analyze data, view machine performance,
and schedule machine preventive maintenance
• Easily collects data on a 24x7x365 basis with transaction volumes exceeding 260,000 per day
• We can integrate FFH with existing proprietary or legacy systems to derive additional benefit from them
• We can integrate FFH with a material handling system so you can track and then route tires according to real-time and historical process data

Data Collection and Reporting
Collect and store test results from different machines provided by different vendors.
Maintain individual and summarized test results in a database specially designed for optimal reporting performance.
Choose naming convention and unit of measure preference for measurements and reports.
Select preferred distribution for each measurement (Normal vs. Weibull)
Tabular and graphic reports.
Authorize report and management applications on an individual user basis.
We can integrate final finish data to existing order and shop floor databases
Centralized Recipe Management
Save time - eliminate loading recipes via data entry or lap top.
Decrease error – manage a single source of truth for each recipe sent to multiple machines.
Simplify management – each recipe contains setup parameters for different machines (balance, geometry, balance) and functions (testing, grading, marking, sorting).
Add accountability – FFH provides recipe versioning and a quick way to view differences between versions.
Dynamic Production Monitoring
Improve visibility - real-time production counts and status available from any desktop.
See productivity – color-code recipes to identify customer-specific production or non-customer processing (like tooling checks).
Red reserved to indicate time-out exceeded for receiving test result data.

 

 

Advanced Analytics
 
Would you rather spend more of your time finding problems, or solving them? Since 2004 we’ve worked with over 40 clients to successfully design data warehouses and select off-the-shelf data analysis tools to avoid data overload, where:

• Huge amounts of data are completely cut off from the source and stuck in a multitude of spreadsheets.
• Productive hours are lost generating and analysing lengthy reports to identify production and quality trends.
• IT spends too much time developing specialised queries to satisfy user reporting requests.

At the Poling Group, we use proven expertise to organize large, complex sets of data into warehouses and OLAP databases. We assist our clients in choosing the best tools from the marketplace to monitor changing operational status, and offer their staff training to ensure adequate maintenance and support for any data project. 24/7 remote support is always an option.

Select a dashboard tool to monitor production or quality status, by department or across the enterprise, complete with automatic alert capabilities.
The heat map presents volume as block size and status as color. At a glance, you can quickly discern what problems demand your immediate attention.
Once you identify a problem, use drill-down tools to quickly determine root cause.

At Poling Group, the future is available now.

 
 
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