How to Use Amper to Justify Lights-Out Production & Capex Decisions

Featuring Destaco-Mt. Juliet

real time visibility case study

Destaco-Mt. Juliet, a Dover Company, partnered with Amper back in January 2020. While they primarily used the system to monitor utilization and downtime, the team at Mt. Juliet wanted to explore lights-out production on pallet pool machines to help cut labor costs and increase overall throughput. Find out how they used Amper to do this, while justifying an investment for 2 more machines.

Highlights

Location

Mt. Juliet, TN

Industry

Industrial Products

# of Employees

134

Lights Out Production

Lights-out production is an approach to manufacturing where no human intervention is required to run a machine for a specific duration of time. Normally, it can be difficult to understand how beneficial adding a lights-out shift is since no one is around to monitor the machines as they run. To get the data you need, it usually requires paying someone to stay overnight to monitor output and track when the machine goes down. This takes time and can often be inaccurate.

However, Amper’s machine monitoring system can help. The team at Destaco-Mt. Juliet was able to automatically track the utilization data needed to do this—without the hassle of overtime and extra paperwork.

destaco lights out

The Approach

First, the team added a 24 hour shift to Amper (shown below in orange) to see how the machine could perform during lights-out production.

Then, they ran one of their pallet pool machines on lights-out production to track utilization.

To determine if it was working, they looked at the utilization dashboard week over week. The results showed utilization remained over 80% for the full 24-hour day even with the lights-out production!

amper for lights out production

After that, the team at Mt. Juliet kept the machine running all day and used it as a benchmark to prove the impact of lights-out production.

The Results

Destaco-Mt. Juliet tested lights-out with Amper over 8 weeks. At the end of the 8 week-test, they found that their pallet pool machines could maintain solid utilization numbersgiving them an extra 4 hours of capacity each day. 

destaco lights out results

The test proved that lights-out can work on these machines, and moreover, Amper’s system showed them exactly when the machine stopped working overnight. 

destaco and amper

Armed with this information, the Mt. Juliet team began transitioning more production from non-pallet pool machines to pallet pool machines and justified the purchase of 2 additional pallet pool machines!

“Amper played a pivotal role in helping us test lights-out production. Because we could collect the data automatically, it saved us time, paperwork and money.”


Continuous Improvement Manager
, Destaco – Mt. Juliet