Background
Terex is a global manufacturer of materials processing machinery and aerial work platforms. It designs, builds, and supports products used in construction, maintenance, manufacturing, energy, recycling, minerals, and materials management applications.
Terex (Dungannon) introduced output.industries’ complete manufacturing analytics platform, Busroot, in January 2024 to measure machine utilisation and capture accurate periods of downtime within the machining processes.
Terex (Dungannon) sought to provide site teams with a comprehensive overview of machine utilisation, including the reasons for any unplanned downtime that reduced utilisation.
Challenge
Existing legacy machines without connectivity
Varying machine types, brands, and age of the machinery made it difficult to capture accurate data.
Unable to connect existing data to shop floor dashboards
It was not an option or possible to monitor eight siloed software programs from each machine supplier/brand they operate.
Lack of a data-driven decision making
The site team had a gut feeling that utilisation was below target, but they could not back this instinct with reliable real-time data across all machines.
The Terex (Dungannon) team's unwavering commitment to innovation and continuous improvement led to excellent insights and significant improvements in such a short period. I’m excited to see Busroot's roadmap come to life across 2024 and the expansion across Terex (Dungannon).”
Mike Wright | output.industries CEO & Co-Founder
Solution
Terex (Dungannon) installed the Busroot platform on several plasma cutters and press brake machines, immediately providing reliable real-time data on machine utilisation.
This resulted in enhanced downtime capture and enabled the manufacturer to identify areas for process improvement and cost reduction.
Thanks to improved communication between managers and machine operators and interventions informed by analysis of downtime data, Terex (Dungannon) was able to improve the quality of consumables and reduce downtime and waste.
Since the installation of Busroot, Terex (Dungannon) has observed improved machine utilisation levels; initial levels were 82% per cent in Q4 of 2023 and 93% per cent in Q1 of 2024 without the need to increase headcount.
Impact
Data-Driven Decision Making
Reliable, real-time data is now powering discussions in daily meetings to understand accurate machine utilisation and dive deeper into downtime causes.
Increased Machine Utilisation
Eleven per cent increase in machine utilisation within three months without increasing headcount.
Reduced Downtime
Accurate tracking of downtime within each shift has ignited process improvement projects to reduce the biggest downtime reasons.
"Using Busroot has helped us gain invaluable insight into our cut shop operations as part of our digital roadmap improvements. We have been able to increase our utilisation, output and efficiency without increasing the headcount. The Output Industries team have provided first class support during start up, and are responsive to making improvements to the software as required.”
Matthew (Bobby) Taylor | Terex (Dungannon) Senior Engineering Manager
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