Weir Increased Throughput
& Reduced WIP
Quality First Pass Yield
Weir Minerals European Manufacturing Headquarters is located in Todmorden, U.K.. The facility specializes in the manufacturing and assembly of specialist and high duty pumping systems. The product portfolio ranges in weight from around 3kg up to 19,000kg and when fully assembled can be in excess of 45,000kg. These products are made in a range of proprietary controlled alloys and service a global market.
Weir needed to significantly improve manufacturing performance, and increase asset utilization. Their vision was to align value streams to enable a lean manufacturing philosophy. To do this they needed real-time data availability to enable critical decision making. They decided to digitally transform the management of their manufacturing operations from a mix of manual and paper-based processes as well as outdated systems to a cloud-based MES solution that could support the company’s Industry 4.0 strategy.
Different manufacturing operations: foundry, machine shop, laser cladding, assembly and a digital additive manufacturing center, needed the same MES solution to provide real-time data visibility, process and quality control. They also needed seamless integration with the ERP system and manufacturing equipment.
Weir was looking for a partner that could not only solve their existing manufacturing problems but also support their global deployment strategy. After an extensive vendor selection process, 42Q was chosen as the new MES for Weir’s facility in Salt Lake City, U.S.A.. Implementation of 42Q’s Digital Factory Starter Kit at the facility enabled significant operational improvement including lead-time reductions of 30% for some products. As a result of the positive impact of 42Q on Weir’s manufacturing operation in Salt Lake City, the company decided to roll it out across all plants worldwide.
- Increased foundry throughput by 53%
- Reduced WIP inventory by 37%
- Improved first pass yield from 90% to 99.1%
See How Our Customers are
Transforming Their Businesses
Weir Minerals Reduces Manufacturing Lead Times by up to 30%
Weir Minerals, a part of the Weir Group plc, is a global market leader in the supply of engineered solutions and aftermarket products to the mining industry. Their customers require fast order fulfillment lead times, which are met by manufacturing products as quickly as possible within their 12 core manufacturing plants.
42Q Enables Production Readiness to Double the Volume at Comet’s Penang Facility
Comet’s facility in Penang, Malaysia needed to double the production volume of matching networks within a period of six months. While the manufacturing process itself could support the increase, the manual data collection process had reached the limits of its capability. The company needed to increase efficiency, improve quality, enhance traceability and wanted a single source of truth for all manufacturing data. They decided to implement a Manufacturing Execution System (MES) and eliminate all spreadsheet and paper based processes. They also wanted the system to seamlessly integrate with their ERP system and a variety of manufacturing equipment.
Cloud MES Supports Sophisticated Automation in a High Speed, Highly-Regulated Manufacturing Environment
A global medical device manufacturer had been producing complex Class II medical devices for years, using 42Q as their MES. Now they faced the challenge of manufacturing high-volume Class III medical devices with complex, fully automated production lines. They feared that implementing advanced, high-volume automation using 42Q MES would require significant factory downtime. The new production lines required a high level of sophisticated automation and a manufacturing execution system that supported and seamlessly integrated with such systems.
Digital Factory Transformation with 35,000 Pieces of Manufacturing Equipment Connected in the Cloud
Sanmina manufactures 250 million products per year. More of a challenge is that there are over 200,000 different top-level assemblies produced each year for 700 different OEM customers with up to 20,000 forecast changes per week. The OEMs operate in diverse industries including telecommunications, enterprise computing & storage, industrial and clean technology. A significant amount of production is for medical, aerospace and automotive products with strict regulatory requirements. The existing on-premise MES required significant maintenance and upgrade effort from the IT and operations teams. It was also limited in its ability to manage supply chains beyond the walls of each factory, and was not well suited for factory automation and other IIoT initiatives.