DLoG Case Study - Kohler Mira
Kohler Mira optimises production with DLoG product data management system
Like most manufacturing organisations, leading shower and water control systems specialist, Kohler Mira is continually striving to improve its products and processes.
As part of its on-going programme, the company has recently completed a project which, as well as bringing its IT infrastructure up to date, paved the way for a dramatic reduction in its paperbased product data.
To achieve this, 14 industrial terminals have been replaced by up-to-date industrial PCs and modern production data management software - streamlining the transmission of manufacturing data, and speeding the overall production process.
Based in Cheltenham, Kohler Mira is a 700-strong organisation with an annual turnover of more than 120 million Euros. It is not only the UK market leader for domestic and commercial shower and water control equipment, but has customers, wholesalers and specialist dealers of sanitary equipment throughout Europe, North America and Japan.
Product Optimisation
Prior to the implementation of its new Quadro RM system, Kohler Mira's production documents, such as tool lists, drawings and production sheets, were all created and circulated on paper.
"For production efficiency - and ecological - reasons, we needed to reduce the vast amount paper in our manufacturing departments," says production engineer Derek Bradley. This basic need led to the establishment of a project aimed at modernising the company's DNC and production systems.
Bradley and his colleagues began by developing a specification for the new hardware and software. High on their list of requirements was the need for touch screen operation of modern industrial PCs. To reduce the volume of documents, Mira wanted a Production Data Management (PDM) system that would not only administer all NC programs, but also control tool data, set-up and fixture plans, graphics and text documents. The management of SDRC-CAD files was another important consideration for the project team. Equally, NC programs would need to be transferred to and from shop floor machine tools, as well as to be locked and released. Further key requirements were faster data transmission, system reliability and user-friendliness.
After an exhaustive selection process, the solution proposed by DLoG won the project team's decision.
"DLoG's Quadro RM PDM system convinced us at once," remembers Derek Bradley. "We could see that it would allow us to administer all production data centrally. It also has fully integrated data management from work preparation, right through to the machines - an essential requirement for up-to-date production data at all levels. In addition, the powerful integrated modules for editing or comparing NC programs, plus the display program for graphics and text, provide the platform for an almost paper-free production environment."
the solution in practice
Following a rigorous pilot installation phase, the system was rolled out across Kohler Mira's production facilities.
In operation, all the files for an operation can be retrieved instantly at an operator's IPC terminal. Simple icons make DNC transmissions child's play, while path administration prevents mistakes. The Windows-based and easily configurable user interface is equally impressive; not just because it makes the work of the machine operators simpler, but also because it minimises training time and costs. Furthermore, WinWord or Excel files can be displayed just as readily as graphically based drawings or photos - a key requirements for the electronic transmission of production data.
The system's flexibility has not only streamlined the company's new production processes, but also paid off in terms of data exchange. DLoG's Quadro Exchange software has been used to prepare and export legacy data from the old system and seamlessly import it into the Quadro RM database without any problems.
Following initial training and implementation by DLoG engineers, members of the project team have been able to instruct their colleagues in the solution themselves. In particular, the logical and user-friendly interface of Quadro RM - with its electronic folders comprising two hierarchical levels - has met with a positive response from users.
Kohler Mira maintains all data required for manufacturing components at the 'parts' level, while the 'operations' level holds all the information needed for the individual operation. In this way, the company also administers all NC programs, together with tool lists and tool pre-setting data, parts drawings and production sheets, quality control information and photos of complex fixtures.
"The IPC's touch-screen interface allows machine operators to retrieve a job folder instantly," explains Bradley, "And, unlike before, the complete job is always available. Searching for individual, scattered documents is now a thing of the past."
paying off
Bradley and his colleagues are very satisfied with their choice of Quadro RM, Tip DNC and the industrial PCs from DLoG. "Together, we have carried out the project smoothly from A to Z," he notes. "The costs for hardware, software and service were calculated accurately on both sides; so the investment has stayed well within budget."
"And it's already paying off," he adds. "Quadro RM is fast and reliable. Production documents can now be retrieved quickly and conveniently - enabling us to speed up productionand reduce our costs."
Not surprisingly, plans to extend the use of the system at Kohler Mira are already in hand.
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