Implementation site: Hydraulic Elements and Systems PLC, Yambol, Bulgaria
Overview
In 2009, ISEE undertook a project to demonstrate the capabilities of the Business Digital Twin (BDT) software in implementing Single-Minute Exchange of Die (SMED) and lean manufacturing principles.
The Experiment
Between 2009 and 2010, over the course of 18 months, two engineers with no prior experience in plant design or lean manufacturing theory, but highly proficient in the ISEE Business Digital Twin BDT system and its cognitive platforms, developed and implemented a system for SMED and lean manufacturing. This system was deployed across two technological fields, encompassing a total of approximately 40 digital programming operational places.
Outcome
The implementation of SMED resulted in a remarkable increase in productivity, with the 40 operational places in question experiencing a 5 to 10-fold productivity improvement. This was achieved with minimal costs. Additionally, a comprehensive personnel training program was developed to ensure the sustainability of these improvements.
In comparison, developing and rolling out such a system on a global scale within a plant owned by a large Western company would typically take around 6 years, requiring significantly greater human and financial resources. This stark contrast highlights the efficiency and effectiveness of the BDT software in facilitating lean manufacturing practices.