Armstrong World Industries used AVEVA™ InTouch HMI web client to see critical real-time equipment information on the plant floor and improve line performance. Using customized process and maintenance screens, operators have decreased production changeover time, decreased scrap, and increased throughput. This end-to-end real-time visibility has enabled operators to move from a reactive maintenance strategy to a proactive strategy and act on emerging issues before they become downtime events.
“We no longer needed to wait for a production summary each hour to know if any changes had been successful. We now know within five minutes.”
—Joe Alba,
Value Stream Manager, Armstrong World Industries
Goals
- Lack of visibility into operational data on the plant floor
- Needed to bring IT and OT sources into the same solution
- Wanted to improve manufacturing line performance at a faster rate with sustained results
- Cost and time to deploy across the business
Solution
- Deployed AVEVA™ InTouch HMI web client to gain real-time production line data across all mineral fiber manufacturing sites.
Results
- One line saw a changeover reduction time of 21%
- Average changeover reduction by four minutes, creating over six hours additional capacity
- Identified a maintenance issue with one of the feeders that enabled a quick solution, with an overall throughput gain of approximately 7,500ft2
- Faster real-time information of scrap causes resulted in a scrap reduction of around 0.25%
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