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Recently, the AIMMIRAI Lean Smart Factory Cloud Platform - Andon System, implemented by the ALSI Smart Factory digital transformation team for a household products company specializing in wet wipe production and export, has been successfully delivered. This system aims to assist the company in building its smart factory, reducing downtime losses, and increasing existing production capacity.
As a young manager of a family-owned business, General Manager Mr. Wang studied and worked overseas for many years. After returning to China, he participated in large-scale digital transformation projects at several well-known foreign-funded manufacturing companies, giving him a deep understanding of digital transformation in manufacturing. After taking over the company, amidst the collision of traditional management models and digital management thinking, Mr. Wang has been actively thinking about and seeking new models and methods for digital innovation management.
In recent years, with the rise of the "machine replacing manpower" trend, the number of operators on the workshop floor has been gradually decreasing, while the problems each operator faces and needs to solve have become increasingly complex. This company's workshop faces the same issue. Since each worker needs to monitor multiple machines, they often fail to detect and report equipment anomalies in time, prolonging abnormal equipment handling time and even causing delivery delays due to equipment shutdowns.
Since the business is mainly export-oriented, delivery delays can affect the company's reputation. Meanwhile, constraints on current workshop capacity often require overtime work and expedited shipping to ensure delivery deadlines, adding significant cost pressure to the company.
To reduce downtime losses caused by anomalies, Mr. Wang hopes to gain a more transparent and clear understanding of workshop production conditions, enabling timely adjustments in production, procurement, and business operations. He has turned to digital and intelligent system service providers, hoping to receive support from a professional team.
After extensive research and comparison, Mr. Wang ultimately chose the ALSI professional digital team. ALSI conducted a detailed investigation in the company's workshop, working with the client to jointly explore digital workshop management models and systems, ensuring smooth implementation of the system application:
| Install an ALSI TS-10 data collection terminal for each machine, enabling automatic, zero-contact sensing of all equipment anomalies at low cost.
| Equip each machine with an SS--10 IoT button device, and based on workshop requirements, configure button calls for various anomalies and key personnel, allowing frontline operators to convey information with a single press.
| Provide alarm smartwatches for maintenance personnel, material handlers, shift leaders, and the factory manager, enabling timely reception of anomaly information and reducing response time.
| Install several Andon boards in the workshop and management office for real-time monitoring of workshop production status and reasons for abnormal downtime.
Mr. Wang personally led the team in implementing the workshop digital transformation project, helping management and frontline employees build a digital workshop management mindset. The "top-leader-driven project" achieved remarkable results. One month after the Andon system went live, the factory managers had a clear grasp of abnormal workshop downtime, and the average anomaly handling time was successfully reduced by 75%. The effect was very significant, marking a solid step toward the transformation into a smart factory.
