Increasing Efficiency With FreePoint

About the Client

For more than 130 years, Caldwell has created quality spring balances for window manufacturers around the world. Their products are everywhere from homes to schools, office buildings to hotels, even the United Nations Secretariat Building and the Empire State Building.

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The Challenge

One of Caldwell’s primary focusses was looking for ways to increase efficiencies across their plant floor. Experiencing year over year growth, they quickly realized they needed to be more efficient to meet increased demand. With no traceable data to understand why a given machine was not running efficiently after set-up, Caldwell concluded they required a method to more accurately track machine downtime.

The Solution

Deployment began in their CNC machining area, increasing operational efficiency by 9%, translating to +160 hours of additional machine output per month (using the same headcount).  Due to the success in the CNC area, they have now expanded our machine monitoring solution to the stamping area. Caldwell is building on their initial success by deploying our employee engagement solution.

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By engaging operators to use reason codes to narrate the downtime on all their machines, Caldwell is positioning themselves to see continued and ongoing efficiency increases.

Increase Operational Efficiency

Caldwell managed to increase overall operational efficiency by 9%.

Additional Machine Output

Over 160 hours of additional machine output was freed up per month.

ROI Achieved in Weeks

Caldwell was able to pay off the cost of their solution in mere weeks rather than months.

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