What a T-SIM Plant Looks Like

Everyone recognizes there is no “magic wand” that can be waved to make 100% of your problems go away in a stamping plant. However, it is amazing how many problems can be solved by implementing a proven system for optimizing your production and eliminating many of the most common pain-points you experience.

All plants face a wide variety of challenges that add stress and reduce efficiency. It’s not unusual for press and transfer lines to receive little or no preventative maintenance. Project launch times can take multiple shifts, or in some cases, require tooling to be modified just to make it run. Most tools are running below the quoted SPM rate, and very few people can even tell you why. Scheduling is a nightmare, and deadlines are missed on a regular basis. Press capacity is maxed ou,t and overtime pay is off the charts because they have to work 3 shifts 7 days a week to keep up with orders. Staff turnover is a constant issue, wasting thousands of hours re-training over and over for the same positions (often due to burnout). Trying to figure out how to deal with these problems can seem overwhelming, but T-SIM can help. We have a number of customers who once experienced these same struggles, but by working closely with them to implement T-SIM into their organizations, they no longer deal with the stress and poor efficiency.

Typical Plants:

• No time for preventative maintenance (PM)
• Long project launch times
• Tools running below quoted SPM
• Scheduling conflicts on a regular basis
• Missed deadlines
• (3) shifts / (6-7) days a week
• Maxed out press capacity
• High turnover / low employee morale

T-SIM plants have ample time to maintain their equipment, and have increased the longevity of that equipment, reducing overall capital expenditures. They launch projects in less than one shift, and routinely meet or exceed their projected SPM production rates. Their scheduling is very efficient, and the on-time delivery rates are at or near 100%. They have open capacity in their presses and have reduced their labor costs significantly by dropping a shift and running 5 days a week. Employee morale and retention are at all-time highs, and the overall profits for the facility are higher than other plants.

T-SIM Plants:

• Well maintained equipment with regular PM scheduled
• Projects launch in less than one shift
• Tools meet or exceed quoted SPM
• Schedule runs smoothly and there is time to deal with un-expected issues that can occur
• Deadlines are met and customers are happy
• (2) shifts / (5) days a week is sufficient to meet orders
• Available press capacity to pursue new opportunities
• Employee retention and morale are noticeably improved

There is no “magic wand” required to accomplish this. These plants simply follow a proven process to optimize their existing tooling, simulate new tools before they are built, and plan out all future tools using T-SIM software. The proof is in the numbers... T-SIM plants increase their productivity on average by more than 40% over the first year of implementation. This translates to millions of dollars per year and open press capacity to pursue new work that will be profitable. Sounds too good to be true? We would love to show you! Let us work with you to optimize (3) of your projects to show you just how beneficial T-SIM will be to your organization.