In July 2019, the TRUMPF Smart Factory Consultants from Ditzingen and their colleagues from TRUMPF Korea started to carefully examine AutoLink's production. They discovered optimization potential in the production sequences and developed customer-specific recommendations for action for AutoLink. The objective: increase the productivity at AutoLink and improve delivery reliability with transparent and ideally coordinated production processes. To do so, they needed to ensure a precise overview of the machine utilization and the material inventory at all times. Park says, "We tested various machine monitoring solutions with the consultants and decided to introduce the TruTops Monitor. This condition monitoring system records and analyses machine data automatically." This means that every time there is machine downtime, it is possible to analyze if it was caused by a machine fault, or a different reason – for example, a sluggish workflow as material was not in the machine at the right time.
When moving into a new production hall, the TRUMPF Smart Factory Consultants supported AutoLink in replanning the production from scratch. A new, process-oriented hall layout was designed to assist the optimized processes from the very beginning. New process standards were created based on lean management method 5S. So-called shop floor markings now indicate zones where staff are not allowed to store materials, among other things. This ensures that the colleagues can reach the machines quickly at all times. As well as the existing machines, the consultants also included the new laser tube-cutting machine TruLaser Tube 7000 in the plans. This machine really distinguishes AutoLink from the competition in South Korea. The KPIs determined by the TruTops Monitor form the basis of the shop floor meetings at AutoLink, which are now held on a daily basis. Park says, "The transparency created by TruTops Monitor and the many small and large solutions, developed in data-based shop floor management, have already increased our productivity by 30 per cent."