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Remote Guidance during repairs of machine

Company : Vega Controls Pvt. Ltd.
Machine : CNC Turret Punch Press ( TPP )
Make : Amada, Japan

Scenario: Month of March, the entire manufacturing team is working under tremendous pressure of year-end commitments & are committed to achieving the targeted turn over. For fulfilling the order requirements which are customer commitments, the main feed is coming from Fabrication shop & the heart of Fab shop, the Amada CNC TPP is being run all 3 shifts non stop all 7 days of the week.

It is Friday & the second shift operator is busy with his given load when suddenly the TPP stops.
Although not much experienced, being a sensible person, the young Operator realizes the importance & seriousness of the alarm which indicates that the Operating Hydraulic Oil Pressure has dropped down & is below the required level.

He cannot afford to stop the machine & he has a commitment to deliver a specified load for Friday Third shift Bending machine
( Press brake ) & which in turn is feed for Saturday first shift Welding shop.  But at the same time he is not supposed to run the machine either when there is an error alarm which may lead to major machine brake down which in any case is not desired.

He contacts the Shift supervisor to report the problem. The supervisor in turn contacts the Amada team for emergency support & requests for online support. The Amada technician tries to explain the procedure but it is noted that the required message is not getting conveyed over the phone & the technician himself has to attend the machine to sort out the issue. He being on duty at a place about 250 km from Vega Factory & is unable to reach before the next day morning even if he starts immediately. Plus he is stuck in attending another brake down maintenance problem which he cannot leave halfway. The earliest he can reach Vega is Monday morning.

This means loss of 7 shifts production …. this will create havoc at the panel assembly & wiring shop where a  team of 30 wire men is waiting for the fabricated panels to start & complete their job before handing over to testing.

Here comes VirGo Virtual Mobility kit into the picture !

The supervisor requests the Amada technician to attend a web con on the VirGo platform. The supervisor hosts the session, the maintenance technician at Vega acts as a glass user & Amada technician is the invitee, a guest who is an expert in the field.   

Through the glass user, the Amada technician virtually stands in front of the CNC TPP machine. Sees the alarm signal displayed on the control panel. Refers his manual, uploads his diagrams in the meeting, shows the operator exactly what needs to be done & explains him the procedure. Gives him the run-time instructions. The glass user views all the directions on the glass screen & understands the instructions exactly & acts accordingly while the technician observes the steps being taken & confirms them online.

The machine gets back to working conditions within a couple of hours & saves downtime of 7 shifts which is 56 hours! The monetary value of this can be in many lacs apart from the value of meeting customer commitment which is invaluable.

Have an Active Vision, Strategy, & Roadmap to Reach Your Goals

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Scale & Maintain Healthy Operations & Culture

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I Also Give Hands-On Workshops & Talks

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