- April 18, 2011
- Case Study
The EMAP system includes the deployment of several Apple iPads to the flow meter production line, including assembly, testing and shipping operations.
April 18, 2011 - Racine Federated Inc. (RFI) implemented the EMAP (Electronic Management of Assembly Process) program as the next element in the corporate efficiency plan. The new EMAP system includes the deployment of several Apple iPads to the flow meter production line; including assembly, testing and shipping operations. EMAP eliminates virtually all paperwork, moving RFI further in the direction of a paperless and sustainable operation.
EMAP operates with each person obtaining an iPad from a charging station and logging in. The system will then instruct personnel on the type, quantity and priority of flow meters to build for that day. When assembly is complete, product is moved to testing/calibration and then on to shipping. Each department follows a similar process using the individual’s iPad. Included in EMAP process software are pick-lists, inventory locations and individual work instructions. Terry McDonald wrote all corresponding software for EMAP, which connects the iPads to Racine Federated’s MRP system through a secure Cisco wireless network. According to McDonald, “Our material resource planning system was quite easy to connect to the iPads and programming was straightforward. We are continuously adding new features improving operator interface and program performance. Another highlight to EMAP is the immediate Engineering updates, and the automatic sync of bills of materials, assembly procedures, routing and testing, or parts.” RFI initiated a comprehensive sustainability program in 2005, through the consolidation of all divisional operations into one new Racine facility. Subsequently, RFI began to develop other programs to increase efficiency and encourage economical and environmental improvements. The EMAP program is one of these developments supporting paperless efforts. David Perkins, President of Racine Federated, Inc. stated, “I wanted to improve our entire manufacturing operations and reduce our paper consumption. Not only did EMap do that, but the program also improved overall efficiency.” Shannon Rollins, Manufacturing Manager and Terry McDonald, MIS Manager were leaders in the EMAP project and are pleased with the positive impact it has had in RFI’s operations. Shannon Rollins stated “We came up with a program to reduce our paper consumption, and the iPads have provided us with positive results in more areas than originally planned. We now have automatic labor tracking, improved quality, a reduction in work instruction time, and a fully enhanced production process.” EMAP has been a success for RFI as well as employees. The ease of operation has improved labor time and quality. RFI’s sustainability programs are being developed to improve operations including energy consumption, recycling, streamlining processes, and paper reduction. Energy reduction programs have focused on improvements to the HVAC systems, improvements in lighting, temperature control, boiler monitoring and insulation. Future programs include broader based recycling programs and additional energy efficiency improvements. About Racine Federated Inc. Racine Federated is a privately held manufacturer of flow meters and internal concrete vibrators celebrating forty years of continuous operation in Racine, Wisconsin, USA. Products are sold under the following trade names: Blancett, Dynasonics, Flo-tech, Hedland, Preso, Racine and Wyco. Racine Federated products serve construction, industrial, petrochemical, oil and gas, energy management and many other markets worldwide.Learn More
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