How did Hamat plant improve standard cycle times by 10-15%

LeaderMES makes our job better and easier and enables us to quickly analyze the data, get to the source of the problem and solve it. It’s a remarkable tool to have

By Elad Arbiv, Hamat factory manager
Download Hamat case study in PDF

Our Key Challenges:

The Need for standardization & breaking production bottlenecks

When I joined the Hamat team as Factory Manager in 2017, my goal was to gain control over the company’s production process. Hamat is a profitable company, but today every factory needs access to data so it can elevate its relevant advantage, develop a competitive edge, and beat the competition.
I was searching for a technological system that would enable me to do two main things:

1. Collect data from the production lines in order to standardize the manufacturing norms by understanding the gaps between the manufacturing potential of each machine and its efficiency in real-life.
2. Identify and analyze production bottlenecks, and present a solution to resolve them and optimize production processes as a whole.

Choosing & Implementing LeaderMES:

Digital, Online, Easy to implement

Following a thorough examination of leading relevant solutions on the market, we decided to choose LeaderMES, an innovative tech company that develops software that combines pervasive technology and manufacturing know-how to digitize factories’ production process. We chose LeaderMES over other solutions we reviewed because it was the only platform that allowed for online management and control, provided full support and could back its promises with plenty of successful integration stories in similar factories.

We began implementation in February of 2018, and almost immediately were able to access important information and receive online notifications of anything and everything going on in our factory, at any given time.

The platforms were rapidly assimilated within our existing systems, highlighting bottlenecks and influencing redirection decisions. It granted me access to a comprehensive view of every machine, at any given moment from the comfort of my cell phone.

This is a huge added value for me. This system allows me to set standards, streamline the cycle times of the parts, and eventually reach OEE.

The implementation process of the LeaderMES platform was relatively easy. There were certain machines that needed to be characterized and redefined; one machine in particular gave us a lot of headache, and it was critical that we’re able to see it. But once we understood where the problem was, Eureka! We realized that we could implement the solution in other machines, and at that moment the road was opened to full integration of the LeaderMES platform in the factory.

Part of the implementation was having our factory workers getting used to being asked questions every time their machine stopped. Change is difficult to most of us, but once a person is aware that his machine is monitored, he suddenly responds differently, operates differently, and as a result, production times shorten.

The Benefits to Hamat:

Improved production cycles, better output, higher operational efficiency

“LeaderMES makes our job better and easier and enables us to quickly analyze the data, get to the source of the problem and solve it. It’s a remarkable tool to have”

As soon as we integrated LeaderMES we could identify the production bottlenecks and deal with them. It became a routing process as we worked closely with the LeaderMES sensors to find the production cycle time of each machine and improve it, find the standard time and improve it and so on. Once you can identify your production bottlenecks – you’re in control and it’s a lot easier to deal with the operational challenges.

In order to find our OEE we had to start by collecting cycle times for all parts from all the machines. This database is now in its final stages of fine tuning; once we started seeing patterns and repetitions and once the workers realized the benefits of having their machines monitored, we started seeing improvements of 10-15% in standard production cycle times. This contributes to our output, and allows us to load more jobs.

Company Overview
Hamat is the leading and largest faucet manufacturer in Israel, developing, manufacturing and marketing high quality faucets with innovative designs. Hamat employs roughly 200 workers at its Ashdod factory, ensuring that all stages of faucet manufacturing run smoothly and successfully, from casting and machining, to polishing and finishing. The company’s seamless operations are what secure its position as one of the Israeli market’s leading exporters.

Hamat is one of four subsidiaries of the Hamat Group (Merhav), which specializes in the manufacturing, marketing and exporting of a wide array of products designed for bathrooms and kitchens, specifically bathroom faucets, kitchen faucets, showers stalls, installations and sanitary products. The Group, which was founded in 1944, is a public entity, and has been traded on the Israeli Stock Exchange since 1993.