Festo Improve OEE Using Industry 4.0 Insights

Here’s how they did it:

Scharnhausen, Germany, is the location of one of Festo’s latest production facilities. It’s also the location for an Industry 4.0 initiative which saw state-of-the-art production technology integrated with a forward-looking maintenance programme. The aim was to improve Total Production Maintenance (TPM) and Overall Equipment Effectiveness.

The first step was to equip maintenance engineers with the latest digital technology, to help improve efficiency and provide immediate access to information and resources. The iPad tablets now carried by Festo’s service maintenance personnel are connected by Wi-Fi to over 100 machines, and to the factory’s Manufacturing Execution System (MES). This gives engineers access to information including up to 15 years’ worth of service history, manuals and repair instruction for each machine, notification of pending and current problems, and scheduling of maintenance tasks.

Being able to email and chat while on the move also makes it easier for personnel to collaborate on maintenance tasks, while direct access to the MES allows real-time information uploads and parts stock checks.

In less than six months, Festo’s initiative saw a significant ROI, in four ways:

• Less travel time
• Reduced repair time
• Improved efficiency
• Improved OEE

The Scharnhausen production facility is also a ‘Learning Factory’, where employees can upskill and acquire practical knowledge. Festo has its own training and consulting division – Festo Didactic – which trains operators on new technology, and continuous learning is part of the culture for all employees.