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Lincoln Manufacturing’s implementation of Mingo Smart Factory transformed their approach to data acquisition and production monitoring. The real-time insights and significant cost savings achieved through Mingo enabled them to optimize operations, improve decision-making, and establish effective OEE targets. Lincoln Manufacturing saved $100,000 in efficiency and by eliminating paperwork.
Lincoln Manufacturing specializes in automotive stamping, focusing on producing transmission parts and essential components for the undercarriage and underhood, such as sound dampeners and brackets.
They use many varieties of steel to manufacture parts ranging in thickness from 0.6mm to over 6mm.
For years, Lincoln Manufacturing struggled to find a suitable system to capture and analyze their production data. They initially explored ERP systems but found them lacking in the specific data acquisition capabilities they needed. The company relied on an outdated pen-and-paper system for recording downtime and control sheets, which was prone to errors and inefficiencies. Dan Rhodus, the Quality Manager, realized the need for a robust data acquisition software to gain insights into their operations before making any significant changes.
Mingo Smart Factory provided Lincoln Manufacturing with a powerful solution to capture real-time data from the factory floor. This transition from manual record-keeping to digital data acquisition revolutionized their operations. According to Rhodus, “We want to get data from the floor in front of our leadership crew, and we can do that now with just a few clicks.”
This instant access to live data replaced the cumbersome process of searching through filing cabinets for old records. With Mingo, they could view performance metrics and machine statuses in real-time, allowing for immediate decision-making and problem-solving.
By implementing Mingo, Lincoln Manufacturing saved over $100,000 through reduced paperwork and improved machine efficiency. The accurate and timely data provided by Mingo eliminated inefficiencies and streamlined processes, showcasing the financial benefits of adopting advanced production monitoring systems.
Lincoln Manufacturing’s switch from a manual pen-and-paper system to Mingo’s real-time data acquisition enabled immediate access to critical performance metrics. This transition facilitated prompt decision-making and problem-solving, significantly improving operational efficiency.
The real-time insights gained from Mingo allowed Lincoln Manufacturing to establish and monitor OEE benchmarks, something they lacked previously. This newfound visibility helped them identify performance issues promptly and take corrective actions, driving continuous improvement in their manufacturing operations.
Implementing Mingo resulted in substantial cost savings for Lincoln Manufacturing. Rhodus shared that simply reducing the time spent on paperwork and improving machine efficiency saved the company over $100,000. “We made a spreadsheet when this project started. If we could save five minutes per operator on just paperwork, that was a $25,000 savings,” Rhodus explained.
“If we could save fifteen minutes on machine time, just being more efficient, things like that where you didn’t have to do paperwork, it was going to save $75,000. We have easily saved over $100,000 just in efficiency and paperwork alone.”
Before using Mingo Smart Factory, Lincoln Manufacturing did not have specific OEE targets. There were too many different lines to track using pencil and paper to know where to start.
The real-time data provided by Mingo allowed them to establish and monitor OEE benchmarks. They found that maintaining an OEE of 65-70% indicated good performance, with some areas achieving 85-90%. This newfound visibility helped them identify when performance dropped below acceptable levels, prompting immediate corrective actions.
The engineering team benefited from Mingo Smart Factory’s integration with their maintenance software, Faciliworks. This integration ensured accurate shot counts for die preventive maintenance, further enhancing operational efficiency and tool longevity.
Mingo’s capabilities extended beyond data acquisition to improving overall production monitoring and preventive maintenance. The production manager received daily dashboards, eliminating the need for paper-based records and manual inventory counts.
This digital transformation streamlined operations and improved accuracy in tracking production schedules and inventory.
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Lincoln Manufacturing immediately saw the benefits during the trial period. They obtained real-time OEE numbers, accurate counts, and detailed downtime reasons. Rhodus noted, “It was just such an influx of information that we thought we really need to put this on other places.”
This immediate access to detailed data allowed them to compare the performance of different dies and tools objectively. They discovered that some dies, which were previously believed to be efficient, actually had consistent issues requiring adjustments throughout their runs. This insight prompted engineering teams to take necessary actions to improve tool performance.
Looking ahead, Lincoln Manufacturing plans to leverage Mingo Smart Factory for quality checks, aiming to eliminate the last remaining paper-based processes on the production floor. Quality technicians will use iPads to conduct and record quality checks, further enhancing real-time visibility and accuracy.
Where we’ve come from to where we’re at today, and where we’re going in the future. It feels like we’ve updated ourselves from the 1980s to the 2020s. It’s light years from where we were.
Lincoln Manufacturing, Quality Manager
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