MachineMetrics > Case Studies > Optimizing Equipment Utilization: A Case Study of Wiscon Products

Optimizing Equipment Utilization: A Case Study of Wiscon Products

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 Optimizing Equipment Utilization: A Case Study of Wiscon Products - IoT ONE Case Study
Technology Category
  • Analytics & Modeling - Real Time Analytics
Applicable Industries
  • Aerospace
  • Automotive
Applicable Functions
  • Maintenance
  • Quality Assurance
Use Cases
  • Asset Lifecycle Management
  • Real-Time Location System (RTLS)
  • Testing & Certification
  • Training
The Customer

Wiscon Products

About The Customer
Wiscon Products is a precision parts manufacturer based in Racine, WI. The company produces quality parts for a variety of industries, including aerospace, medical, energy, automotive, construction, and power. In 2018, Wiscon began utilizing MachineMetrics at its facility to align with its core goals of process improvement, reduced downtime, and increased equipment utilization. The company wanted to better serve its growing client base and gain complete control of its data.
The Challenge
Wiscon Products, a precision parts manufacturer, faced a significant challenge in data accuracy. The company's manual data collection methods were outdated and inefficient, often resulting in data that was several days to a week old by the time it was reviewed. This lack of real-time data made it difficult for the company to make informed decisions and implement improvements. Wiscon also struggled with gaining insight into production downtime, cycle time, and equipment utilization. The company had questions about how often spindles were turning and how many parts were being produced. Despite investing over $16 million on equipment, Wiscon was always running at capacity, and there were gaps and delays in the data, leading to a lack of visibility and an inability to respond to issues quickly.
The Solution
To address these challenges, Wiscon deployed MachineMetrics at its facility. This resulted in significant efficiency gains across production and provided teams with complete visualization of real-time data. The company was able to shift from a reactive to a proactive approach, driving critical improvements in planning and scheduling processes. MachineMetrics provided critical benchmarking information that helped management understand the value of categorized downtime and accurate production performance. This guided the development of data-driven improvements and empowered actionable decision-making. The platform also integrated quickly with Wiscon’s existing ERP and QMS systems, enabling operators to focus on quality instead of administration and data entry. The extensibility of existing systems gave Wiscon a considerable advantage in using real-time data to improve operator efficiency.
Operational Impact
  • The adoption of MachineMetrics has transformed Wiscon’s production capabilities. Management quickly realized that parts exceeding production goals drove a market opportunity to be more competitive. The company could also use real-time, actionable data to pinpoint problems concerning parts that exceeded cycle time. Teams could now see errors in quotations, process failures, training issues, and more. With access to high-quality, real-time data, Wiscon didn’t need to rely on employees to track problems manually. MachineMetrics’ native workflows and reporting enabled managers to address issues in real time, with data at their fingertips to use as a starting point for improvements in maintenance strategies or training. The company’s bottom line has seen significant improvement.
Quantitative Benefit
  • Increase in average machine utilization by 30%
  • Rise of 30% in overall capacity
  • Increase in average operator productivity by 250%

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