Background / Issues

Improve production control targeting No.1 status in the industry

Absen is a Chinese manufacturer of large LED displays to the global market. Its products are widely used for high-impact performance displays in shopping malls and theme parks, as well as for high-definition information displays in monitor/control rooms and broadcasting studios.
At Absen’s factory, the production control method was dated, and there were major problems in information flow between the production site and production controllers. Additionally, Absen were considering how to increase their production levels with the aim of becoming the industries number one supplier.

Solution

Realization of data conversion and traceability

Absen needed a solution which leveraged deep industry knowledge and offered a far-reaching system of collaboration which together could realize an intelligent manufacturing model that was appropriate for them. So Absen turned to Mitsubishi Electric and their e-F@ctory concept.
Working together they first determined the data they needed to collect, then defined and interpreted the key parameters of each device or machine. Next, the automatic reading of traceability data and results of quality control inspections were added. As a final step, visual control was deployed. By controlling each device’s processes in real time it became possible to prevent defects due to human factors and to stop abnormal situations in their tracks.

Effect

Data can be used both upstream and downstream

Through collecting, analyzing, and visualizing production data, the management team could grasp the status of equipment and production in real time. With the realization of collaboration between downstream and upstream production in the company, close alignment between procurement and sales as well as production could be achieved, thus realizing consistent intelligent manufacturing.

Image: Continuous visualization, analysis and improvement was made possible

SMKL

Digitizing production equipment made data available to the whole company

Level D

Optimize

Making ROI bigger step by step by using SMKL.

Level C

Analyze

Level B

Visualize

Level A

Collect

Level 1

Worker

Level 2

Workplace

Level 3

Factory

Level 4

Supply Chain

“Maturity Model” is a known type of analysis, it also makes the reader think of higher management analysis so is the right way to describe this….because it is actually a maturity model!

Just to make continuous investment is probably a bad business decision but to make that investment sustainable means that it pays for its self and continues to drive value – simply investing continuously does not guarantee benefit – only cost

Traceability

• STEP I A1 :

  Data collection
• STEP II B3 :

  Application to the entire factory

By determining and collecting relevant data at activity, machine and line levels in real-time, a complete picture of the current operations could be grasped. Combining this with tracking each product through the production cycle via a unique code, enabled full production traceability to be achieved. As a final step, this data can be used in downstream and upstream production in the company.