Although SUNSTIGE was a start-up established in 2017, the team’s background was in plastic molding and they’d had success helping a well-known plastics company build a smart manufacturing solution. For these reasons, SUNSTIGE won the favor of I-Liang and together formed a close partnership.
Dr. Ray Tseng, Vice President of SUNSTIGE, said that the introduction process of the project started with the networking ability of the existing equipment. The underlying hardware was constructed first before the software and application requirements of the upper layer were considered. SUNSTIGE’s idea was to integrate the machine operation information gathered with a third-party system such as an ERP, and then establish a connection with the order and the work order to link the entire process from top-level commercial orders to the lower level production aspects.
"We’re a current customer of Advantech hardware. After further contact, we found out about the WISE-PaaS cloud platform
. Although SUNSTIGE specializes in industrial application knowledge, cloud architecture is not our expertise. We need services from partners like Advantech who have strength in industrial applications. Also, the solutions on the WISE-PaaS platform can really speed up our deployment. Thus, we quickly decided to adopt Advantech's software and hardware solutions," he said.
Dr. Tseng said that by using the WISE-PaaS/Dashboard, production status was displayed and visualization quickly realized after the installation. This only took one day—allowing I-Liang to see the status of the plant in the shortest amount of time. Once I-Liang was feeling confident, other information was connected successively.
I-Liang officially moved into the new plant in January 2019 and the machines throughout the entire plant are now live. Kelvin Chang said that as of now, via dashboard visualization, management personnel can clearly see the real-time operating status of each machine in the plant and accurately grasp the start times of the machines to reduce human memory or recording errors and easily master the utilization rate and production progress of the whole plant through digitalization. Moreover, due to the complete mastery and traceability of the data, if any yield is abnormal, the times and causes can be quickly found, statistical analysis can be carried out, and the problem can be effectively solved to prevent recurrence. If there is a problem with any machine, a LINE or email message will be automatically sent for instant notification and quick response. By effectively mastering the production time of the machines, it is also possible to pre-evaluate, prepare for mold changes, and make arrangements early. In doing so, the overall efficiency of the plant has improved significantly.
Based on the success of OEE real-time monitoring, I-Liang and SUNSTIGE are now planning to introduce a smart mold management system to enhance the managerial efficiency of 300 to 500 sets of plastic injection molds. Similarly, the companies expect to build a more comprehensive smart manufacturing management model by adding functions such as mold maintenance and scheduling visualization, as well as integrating with the system for raw material management and control.