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“We want to control all the variables in the process to provide a consistent prod- uct, but we can’t control the weather,” Logan said. “I would tell customers to plan for about 17 days a year when we couldn’t pour their parts.”


7KH GHKXPLGLÀFDWLRQ V\VWHP FRQWUROV WKH PRLVWXUH OHYHO LQ WKH DLU DQG WKH ÀUVW phase of data collection helped pre- dict what days to run it at higher levels. With that success, more variables were collected as data points to help further LPSURYH LWV HIÀFLHQF\ VXFK DV ZKHQ WR turn on fans or whether it operates better with an overhead door open or closed. After initial successes with data col- lection, Palmer launched a system-wide intelligence system. It started with 500 collection points. A year later, it had increased to 10,000 points.


To start collecting data on the plant environment, vice president of engi- neering Jim Lagrant installed tempera- ture and relative humidity sensors on the plant floor and outside. Initially, the information was pulled into a spread- sheet.


“It was a laboratory system and it wasn’t bulletproof, but the vice president, operations manager and president saw the value of this data,” Lagrant said.


By controlling the foundry’s atmosphere on high humidity days, Palmer Foundry does not need to change when it will pour metal to make its vacuum-tight castings.


8 Playing Detective


The intelligence system helps Palmer Foundry arrive at the “why” of some- thing faster than before. By establish- ing and then measuring and tracking various data points related to the equipment, such as water tempera- ture and pressure, Palmer Foundry can identify areas where the equipment is not working properly.


“It saves us hours and days of sleuth- ing,” Logan said. “We can go back and do forensic analysis of all our pro- cesses and our equipment.” One of Palmer Foundry’s semicon-


MELTING POINT


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