How Phoenix Mecano Boosted CNC Production by 40% Without Adding Staff or Machines

Discover how Phoenix Mecano achieved a 40% increase in parts produced by leveraging Datanomix’s real-time production monitoring—no additional labor or equipment required.

In August 2022, Phoenix Mecano North America, headquartered in Frederick, Maryland, implemented Datanomix Production Monitoring. The results were immediate and impressive: a sustained 40% increase in takt time without any additional demand, staff, or machinery

Challenges Before Datanomix

Prior to adopting Datanomix, Phoenix Mecano faced difficulties in understanding real-time activities on their production floor. They relied on manual reports that were often outdated by the time they were reviewed in morning meetings. Inconsistencies and inaccuracies in data made informed decision-making challenging. Unplanned machine downtime had a cascading effect, disrupting 5–10 jobs as the team scrambled to compensate for lost time

The Power of Real-Time Feedback

The introduction of Datanomix’s real-time feedback was a game-changer. Operators became more engaged, turning production into a collaborative effort. With access to real-time data, they could make immediate adjustments and observe the impact of their decisions. Large TVs on the production floor displayed easy-to-understand information, including machine statuses and performance metrics. Simple grades and color-coding enabled the team to quickly identify areas that needed attention to maintain smooth operations.

Enhanced Performance Analysis

Datanomix’s robust analysis tools provided deep insights into operations. Phoenix Mecano could compare current performance with past data to identify trends and areas for improvement. Accurate cycle times, broken down by cutting and touch time, led to better scheduling and planning, significantly reducing the domino effect of delays. In the months following implementation, Phoenix Mecan saw a 40% gain in parts produced!

Using Datanomix, Phoenix Mecano updates its costing and router times based on actual performance data, ensuring precise planning and resource allocation.

“Can I remember what job 4 of the 7 was that I did yesterday? And did I have any problems? Am I going to remember that the next time that job shows its head? This real-time feedback piece has been huge. I can’t stress it enough.”

– William Green, Production Manager, Phoenix Mecano

Seamless ERP Integration

Integrating Datanomix with their existing ERP system was straightforward and required minimal effort from the IT team. This seamless connection provided a holistic view of production, making data meaningful and ensuring engineering targets aligned with actual performance.

“On the ERP side, it was by far the easiest integration that we had.”

– Camila Costa, Manufacturing Systems Engineering, Phoenix Mecano

Empowering Operators

Engaging operators had a significant impact. Real-time feedback empowered them, fostering a sense of ownership and accountability. Visible performance metrics created healthy competition, driving continuous improvement. Operators could see the immediate impact of their decisions, which boosted morale and encouraged better choices.

“There’s a little bit of banter out on the production floor. Hey, I’m an A+, you’re a B, what’s going on over there on that machine? What job are you running?”

– William Green, Production Manager, Phoenix Mecano

Optimizing Tooling Costs

Phoenix Mecano appreciated the frequency and speed of new feature rollouts. One notable addition was the tooling reports, providing detailed insights into tool usage. These reports helped optimize tool life, reducing costs. Insights into tool performance also informed purchasing decisions, such as investing in higher-performing tools that ultimately lowered tooling expenses.

Proactive Issue Management

Another impactful feature was the notifications system and the Mobile App. Phoenix Mecano set up real-time alerts for issues like extended machine downtime. For instance, if a machine were down for more than 20 minutes, a supervisor would be notified to assist. If downtime exceeded an hour, the production manager received an alert. These escalating notifications ensured small issues didn’t escalate into major problems.

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