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Rhopoint

Rhopoint Instruments manufacture test equipment that primarily focuses on appearance quality. Managing Director, Tony Burrows, realised that shop floor productivity was falling short of his expectations.

Problem

Their previous production process that used traditional batch building methods, complimented by paper and PDF work instructions was preventing them from achieving their full potential.

Tony reached out to a consultant for support with moving to a lean production process that included six sigma and Kaizen practices, initially to improve just productivity.

Solution

A large part of their transformation included the implementation of a Manufacturing Execution System (MES). After comparing a variety of MES providers, including some of the larger software companies, Rhopoint opted for VisualFactory as they found the software to be faster, leaner and more flexible.

NoMuda also gave them the opportunity to take the time to really consider how it will work with a pilot project, which was a bonus for them.

VisualFactory was implemented in-house using existing staff who had to learn through the training pages and online support provided by NoMuda.

Almost two years since implementation, VisualFactory can be found in production on 80% of Rhopoint products.

Tony has really noticed a difference in the way his team works, “each Workstation is equipped with a vScreen, displaying digital work instructions that provides the operators with visuals to identify the tools and bin location.”

Rhopoint’s initial motivation was to improve productivity, but one of the biggest improvements has been to quality assurance. Product quality is up 35% and customers are visibly happier with their products, as returns are down 70%.

VisualFactory has been really useful for us and has allowed us to improve productivity and grow without expanding our workforce. We can now record check points across the entire operation, which has forced us to look at our products and build in a better way.

Benefits
  • An instrument that used to travel 1850m through the production process now travels just 26m following their lean transformation.
  • Staff morale has also increased, as the operators themselves are much happier that the move from PDF to vScreens has made their job easier, with clearer instructions on what tools they need to be using and when.
  • Rhopoint’s initial motivation was to improve productivity, but one of the biggest improvements has been to quality assurance. Product quality is up 35% and customers are visibly happier with their products, as returns are down 70%.
  • External audits are now much easier given the level of traceability they have with VisualFactory.