PRODUCTIVITY CASE STUDY: MACHINE MONITORING

---

Our client needed to improve performance and optimise machine utilisation across their steel-stockholding business and engaged CHG Group’s knowledge, experience and ability in technology-enabled transformation to develop a programme. We provided Process Analysis and Scientific Requirements capture to provide a firm foundation for the project which led to a demonstrable business case being developed.

Following the business case CHG Group rapidly assembled an experienced team of Software and Development Engineers to develop a product to satisfy the Client’s requirements. CHG successfully completed the Research and Development phase of this project and developed the Machine Monitoring application for our Asset Monitor System. 

The system design provided a non-intrusive, rapid-install cost effective solution for interfacing with existing production equipment to analyse the demand profile, productive time and downtime analysis to provide data to the management team. As part of the Agile development, the client was involved throughout to minimise rework and ensure smooth transition from development to build and factory test of the system. Our team of experienced Project Engineers, Project Managers, Design Engineers, ICA Technicians and Approved Electricians built, tested and installed an operational system in very short timescales that transformed the operation. 

Our team manufactured environment-proof Remote I/O and equipment-mounted instrumentation, combined with Ergonomic Human-Machine Interface terminals and communications backbone, fully integrated with the stringent Cyber Security requirements of the client. CHG completed full equipment safety and operational tests in our labs and workshop to eliminate any issues on site. Design for Installation/Design for Maintenance protocols were built into the design to ensure best-in-class whole-life costing and the safest install and operation for the client.

The results from the first installation far exceeded expectations with an increased Overall Equipment Effectiveness (OEE) of 15% and over £500,000 improvement in profits. The success from our first site, CHG Group then proceeded with the project and installed Machine Monitoring Systems across the whole operation.