Linaset, a.s.

Increase productivity within 3 months.

Linaset has been present on the market for more than 65 years. The company is a tradition, fully integrated supplier of complex projects for the automotive and other industries. It produces high-quality technical moldings, injection molds for the processing of thermoplastics and thermosets and completes construction sets, final products. It operates its production in two plants with a total production area of 10,000 m2 in two production plants located in the cities of the Czech Republic: Budišov nad Budišovkou and Bruntál.

Production portfolio

• Production of molds and injection molds
• Production of technical moldings using thermoplastic injection technologies, including 2K injection
• Production of technical moldings using injection and direct molding technologies for thermo sets, including BMC and SMC materials
• Assembly of components, including ultrasonic welding and laser and pad printing
• Service and repair of molds and tools

Problems of the past

• Limited data collection
• Records of actions only on paper, laborious evaluation
• Absence of TPM method
• Absence of online data monitoring
• Problem with traceability of import data

How did it all start?

• It was 2012 and Linaset has been looking for a solution for a data collection and evaluation towards OEE for a long time. The company was looking for a solution that could be in their hands and did not have to be tied to the source code and the prescribed form of visualization.
• In 2013, Linaset started cooperating with a company from Žilina, which deals with the optimization of production and maintenance processes as well as coaching of key people – IPA Slovakia. As INSEKO and IPA were already cooperating on several joint projects at that time, the ideal solution at that time was to carry out a reference visit to one of PM TOOLKIIT’s customers from the Slovak Republic, who had used PM TOOLKIT for a long time.
• After completing the reference visit, a business carousel was launched, which concluded that a pilot project for monitoring 8 selected injection molding machines would be implemented at the Budišov nad Budišovkou plant.
• After successful completion and evaluation of the pilot project, a roll-out for other key production facilities was gradually implemented.
• Monitoring status today:
  • 56 injection molding machines – Arburg, Engel, KraussMaffei
  • 25 thermosets – Arburg, Engel, KraussMaffei, CBJ, FAHR BUCHER, LAUFFER
  • 9 CNC machines – Heidenhein – Tool shop
  • 30 manual workplaces – assembly
  • 3 robotic workplaces.

• The system is operated centrally on virtual servers
• Operators have at their disposal +20 All-IN-ONE PCs – kiosks in sizes from 15 “to 21.5”.
• In addition to the Operators, the kiosks are also used by Sorters, Masters and Qualifiers
• RFID technology at Kiosks – 125kHz
• New ideas from key users are constantly being incorporated
• Integrated to the internal parent system

General benefits of the implemented PM TOOLKIT solution

• Production control online, visualization on large LCD screens in each hall
• Accurate reliable and unbiased information
• Records of all downtime
• Fresh OEE, quality is recorded continuously
• Introduction of an operation log for Operators
• Multilingual environment for the operator (Polish, Hungarian, Ukrainian, Czech)
• Analysis of production cycles revealed reserves
• Revised standards increased productivity after a few months of monitoring
• Optimized SMED – advanced analyzes, data for optimization
• Acceleration of Reactor reaction times
• Basis for the payment of remuneration linked to OEE
• Detailed reporting
• Implementation of Autonomous Machine Maintenance as part of the TPM, including sending e-mails to defined persons in case the task is not completed
• Introduction of a module for electronic distribution of documents, guidelines linked to the registration of a specific person with an RFID attendance card
• Incorporation of the established production process into an automated electronic system

The PM TOOLKIT solution made it possible to carry out a complete “paperless production”, ie the complete digitization of production took place in connection with the superior system.