Gemba’s GAIN4 ALERT module is so flexible, and totally user-configurable, that it has a huge variety of possible uses.  Let’s take a look at some common ones….

 
Predictive maintenance

Use direct monitoring of equipment condition (eg. vibration, oil, acoustic, infrared) to automatically trigger alerts for maintenance. Including predictive maintenance as part of a comprehensive program allows the availability of process machinery to be optimised and therefore greatly reduces maintenance costs whilst improving product quality, productivity and profitability.

 
Kanban material stocking

Implement an electronic Kanban system to prompt the restocking of your Kanban supermarket with materials from your stores area.

Low equipment OEE or quality levels

 
When equipment efficiency level is falling or the reject level is increasing, you can automatically notify key staff, allowing them to quickly analyse the reason for the problem using GAIN4 ALERT, and take quick and appropriate action to resolve it.

 
Maintenance callout

Automatically alert key staff to equipment downtime - they can use GAIN4 ALERT to analyse the reasons for the problem and act quickly to get things back up and running.

 
Out-of-tolerance process values

 
A process variable such as temperature, pressure, torque settings etc can affect the quality of final goods. Using GAIN4 ALERT to alert staff when these values go outside tolerances will provide you with better control of manufacturing processes and prevent problems before they start.

Multi-stage operations

Use GAIN4 ALERT to put extra controls in to existing processes, ie. to control build sequences in an assembly process. In this case, the operator can be prompted via interactive buttons and work instructions, and each stage can be acknowledged and recorded. The time it takes to complete each step can be measured against the TAKT time for that operation, and alerts can be generated if these times are exceeded.

The ability to monitor your manufacturing process in real-time and alert staff to issues quickly will allow you to maximise production, increase profits and lower costs.