Metal Matic – Enhancing Production Efficiency with Apollo Software
INTRODUCTION
Metal Matic, Inc., a leading metal fabrication company, faced a significant challenge when their main programmer left the organization, leaving them with a gap in their software development capabilities. To address this issue and expand the functionalities of their custom software, Metal Matic sought the assistance of Perceptive Solutions. Working closely with Metal Matic’s internal team, Perceptive Solutions quickly stepped in to develop and enhance the software, now known as Apollo.
The goal was to optimize production processes and provide role-based access to ensure efficiency and security.
CUSTOMER PROBLEM
Metal Matic’s main challenge was the departure of their main programmer, which left them without the necessary expertise to further develop and enhance their custom software. This situation hindered their ability to adapt to changing production requirements and optimize their operations. Additionally, the lack of role-based access to the software posed security risks and reduced staff productivity.
SOLUTION
Perceptive Solutions collaborated closely with Metal Matic’s internal team to address their software development needs. They worked on expanding the capabilities of the existing software, Apollo, which became a robust solution relied upon by Metal Matic’s three shop floors for every production order. The key solution features included:
Role-Based Access:
Apollo implemented role-based access control, ensuring that each user could only access the information and functionalities relevant to their specific role within the organization. This optimized staff productivity and minimized security threats.
Enhanced Scheduling:
The scheduling section within Apollo became one of its most widely used features. It allowed shop floor users to refer to real-time scheduling information that dictated work orders. The scheduler software evaluated future orders, promised dates, available inventory, and other factors to suggest an optimized daily production schedule. This functionality minimized downtime, prioritized customer delivery dates, and optimized production based on factors such as labor and inventory.
Real-Time Machine Throughput Tracking:
Apollo incorporated real-time tracking of the total throughput of the shop floor machines. This data could be used for making informed real-time decisions on order production and also for historical reporting. Analyzing the historical data enabled the shop floor to identify areas for improvement and increase overall efficiency.
Titan Roll Master Suite:
Apollo introduced the Titan Roll Master Suite, specifically designed to track the usage, wear, and tear of rollers used in metal rolling processes. The software monitored the wear patterns of rollers based on different spinning speeds and pressure variations, allowing for timely replacement or retooling to maintain precise tube manufacturing.
RESULTS
The collaboration between Metal Matic, Inc. and Perceptive Solutions resulted in significant improvements in production efficiency and operational effectiveness. The implementation of Apollo software yielded the following outcomes:
Enhanced Productivity:
Role-based access control ensured that staff members had access to the specific information and functionalities required for their roles, reducing distractions and improving overall productivity.
Optimized Scheduling:
The advanced scheduling functionality minimized changeovers and optimized production based on inventory and labor constraints. This resulted in reduced downtime, improved customer delivery dates, and efficient utilization of resources.
Real-Time Data Insights:
The real-time machine throughput tracking capability provided actionable insights for making informed decisions on order production. Historical data analysis further helped the shop floor identify areas for improvement and increase overall efficiency.
Precise Tube Manufacturing:
The Titan Roll Master Suite within Apollo effectively tracked the usage and wear of rollers, allowing for timely replacement or retooling. This precision in monitoring ensured high-quality tube manufacturing and reduced downtime associated with roller maintenance.
CONCLUSION
Overall, Metal Matic, Inc. witnessed a transformation in their operations with the adoption of Apollo software. Perceptive Solutions’ expertise and collaboration helped Metal Matic overcome the challenges caused by the departure of their main programmer and resulted in a highly efficient.