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Recently, Alps Smart Manufacturing (hereinafter referred to as "Alps") reached a deep cooperation agreement with Nantong Dingxin Metal Products Co., Ltd. (hereinafter referred to as "Nantong Dingxin"). The two parties will leverage the Alps Equipment Status Monitoring System to achieve real-time monitoring of production progress and mold usage. This collaboration aims to fully assist Nantong Dingxin in completing the closed-loop digital management of workshop equipment, continuously empowering the dual improvement of production quality and efficiency.
Nantong Dingxin Metal Products Co., Ltd. (formerly Haimen Xingde Hardware Co., Ltd.), established in July 1987, is located in the Economic and Technological Development Zone of Haimen City. It is a comprehensive enterprise integrating new product development, design, and processing. Its products are exported to Europe and America, with notable clients including Volkswagen of Germany and AGCO of the United States.
In the wave of smart manufacturing, Nantong Dingxin has always maintained a spirit of continuous exploration and innovation in technology and management. With the expansion of the enterprise scale and intensifying market competition, Nantong Dingxin faces a series of challenges, including improving production efficiency and stricter quality control. Against this backdrop, Nantong Dingxin expects to strengthen the digital and intelligent management of the production process by introducing Alps' agile, lightweight, and precise smart manufacturing system.
Alps Smart Manufacturing: Fully Empowering Nantong Dingxin
Pain Points of Nantong Dingxin
As a professional enterprise in the automotive parts and hardware manufacturing sector, Nantong Dingxin has seen a continuous increase in non-standard customized orders. To respond more accurately to market demands and achieve another leap in production efficiency, Nantong Dingxin is fully promoting digital transformation construction and has introduced a lightweight MES system, effectively realizing online circulation and full-chain management of documents. However, when it comes to specific production process control, there are still areas urgently needing improvement.
The primary issue is the difficulty in accurately controlling production progress. Currently, production data is manually entered into the system after the fact, making it impossible to effectively guarantee accuracy and timeliness. This makes it difficult for relevant managers to grasp production progress, creating potential risks of delayed delivery to some extent.
Furthermore, issues such as missed mold changes or incorrect mold changes cannot be ignored. Missing a mold change not only directly affects product quality but may also lead to a series of chain reactions, including extended production cycles and raw material cost losses, affecting both delivery and lowering overall production efficiency.
To effectively solve the above problems, the Alps Lean Digitalization Team went deep into the front lines of Nantong Dingxin's production site, conducted multiple surveys on business processes and application scenarios, and jointly formulated a digital solution based on the Equipment Status Monitoring System, with data collection accuracy and real-time performance as breakthrough points. This solution focuses on closed-loop digital management, aiming to achieve transparency in production progress and mold usage, as well as real-time management.
How Alps Empowers
1.Production Progress Control: Real-time Collection of Equipment Output
By introducing the Alps Equipment Status Monitoring System, Nantong Dingxin successfully built an efficient real-time production progress monitoring system. On one hand, relying on the TS-30 collector, it achieves real-time collection of equipment output while connecting with the MES system to synchronize output data to work orders in real time, allowing managers to clearly see the production progress of each work order. On the other hand, the system can also monitor the operating status of equipment in real time. Whether each machine is on, off, or idle, how long it has been stopped, and the reason for the stoppage are all clearly visible. This facilitates managers to target improvements in capacity, thereby improving the control precision of production progress and ensuring the stability and efficiency of the production process.
2. Mold Management: Precise Identification of Abnormal Usage
To address the challenges of mold usage management, Alps equipped the equipment with SS series button counters. Frontline employees must press the button to report after completing a mold change, and the reported data is synchronized to the MES system. This effectively avoids problems such as missed or untimely mold changes, reducing time and raw material cost waste caused by erroneous production. At the same time, the system has established a mold repair reporting and maintenance mechanism. Mold failures are reported via button press, and maintenance duration is statistically tracked in real time, providing strong data support for optimizing maintenance processes and improving efficiency in the future.
The Alps Equipment Status Monitoring System and Andon System, with their excellent real-time performance and accuracy, provide solid technical support for the optimization of Nantong Dingxin's production processes. Through the deep application of Alps' systems, Nantong Dingxin has completed a closed-loop digital transformation from equipment monitoring to mold management. It has not only achieved intelligent monitoring of production equipment but also significantly improved production efficiency, with an expected increase in equipment efficiency of at least 10% and an effective reduction in the defective product rate. This has promoted the development of the production site towards visualization, collaboration, and intelligence, injecting new vitality into the company's digital construction.
About Nantong Dingxin
About ALSI
Alps System Integration (Dalian) Co., Ltd. (abbreviated as "ALSI") is a wholly-owned subsidiary invested in China in 2005 by the Japanese Alps Alpine Group (founded in 1948). It is the Secretary-General unit of the Dalian Smart Manufacturing Industry Innovation Alliance. ALSI has been deeply engaged in smart manufacturing for over 30 years in industries such as automotive parts, electronics and electrical appliances, and mechanical processing. Leveraging the manufacturing DNA of the Japanese group, ALSI delves deep into the "manufacturing site," combining IoT technology, big data, AI, etc., with lean principles to develop the agile, lightweight, and precise "Huipai Supply Chain Resource Planning Platform" and "JinZhi Lean Factory Cloud Platform." It is committed to helping more customers in the manufacturing industry achieve efficient workshop site management and embark on the path of digital and intelligent development.
