How ASH Industries Transformed Injection Molding with Real-Time Machine Data
Saving $1.5M Annually by Reducing Downtime and Boosting Utilization
ASH Industries, a leading thermoplastic injection molding manufacturer, achieved $1.5 million in annual savings by implementing Amper’s real-time manufacturing intelligence platform. By replacing manual data collection with automated machine monitoring, ASH Industries reduced unplanned downtime by 10% and improved machine utilization by 20% within the first month of deployment. This case study demonstrates how real-time visibility into root cause analysis empowers operations teams to uncover hidden capacity, justify capital investments, and drive continuous improvement in complex manufacturing environments.
The Challenge
Moving Beyond Manual Data Collection
Before partnering with Amper, ASH Industries relied on manual, paper-based tracking to monitor their 19 injection molding machines. This process was not only prone to human error but also consumed over 3,000 labor hours annually. Without a "single source of truth," the team struggled to:
- Identify the true root causes of machine downtime.
- Accurately measure machine utilization across shifts.
- Prioritize Continuous Improvement (CI) projects based on financial impact.
The Solution
Rapid Deployment of Manufacturing Intelligence
ASH Industries chose Amper for its non-invasive, plug-and-play approach. After a successful three-machine pilot, the facility achieved full-scale deployment across all equipment in under 30 days.
Key Solutions Implemented:
- Real-Time Dashboards: Instant visibility into which machines are running, idling, or down.
- Automated Downtime Labeling: Operators can easily categorize downtime reasons, providing the data needed for root cause analysis.
- AI-Powered Insights: Using Amper’s analytics to pinpoint the most costly bottlenecks on the factory floor.
The Results: Measurable Impact in 30 Days
Total Annual Savings
Increase in Machine Utilization
Reduction in Unplanned Downtime
Labor Hours Saved Annually
Data-Driven Continuous Improvement
The transition to Amper allowed ASH Industries to move from "guessing" to "knowing." By quantifying the exact cost of every minute of downtime, the CI team could finally prioritize projects that offered the highest ROI. This data-driven culture even provided the justification needed to invest in three new machines to meet growing customer demand.
“With Amper, we can identify and prioritize the biggest areas of improvement on the floor. Our system provides great root cause analysis for our upcoming CI projects.”
Streamline production monitoring & drive continuous improvement
Frequently Asked Questions
Case Study Insights & Implementation FAQ
What was the primary challenge ASH Industries faced before using Amper?
ASH Industries relied on manual, paper-based data collection for their 19 injection molding machines. This process was inaccurate, time-consuming (costing 3,000 labor hours annually), and made it impossible to identify the true root causes of machine downtime.
How quickly did ASH Industries see results from the Amper deployment?
ASH Industries saw measurable results within the first 30 days. After a successful three-machine pilot, they achieved full-scale deployment across their entire facility, resulting in a 10% reduction in downtime and a 20% increase in machine utilization in the first month.
How much did ASH Industries save by implementing real-time machine monitoring?
By using Amper to identify hidden capacity and eliminate operational waste, ASH Industries achieved an estimated $1.5 million in annual savings. This ROI was driven by reduced labor costs for data collection and significantly improved machine uptime.
How did Amper help ASH Industries with Continuous Improvement (CI) projects?
Amper provided the "root cause analysis" needed to prioritize CI initiatives. Instead of guessing where problems occurred, the team used real-time downtime labeling to pinpoint the most costly issues, allowing them to focus their resources on projects with the highest financial impact.
Did ASH Industries use Amper data to justify new capital investments?
Yes. The accurate utilization data provided by Amper gave leadership the confidence to justify the purchase of three new injection molding machines. This allowed the company to expand its capacity and meet growing customer demand based on hard data rather than estimates.
Why is Amper a good fit for injection molding manufacturers like ASH?
Amper’s non-invasive, plug-and-play sensors work on any machine regardless of age or make. For injection molding shops, this means rapid visibility into cycle times and downtime without complex PLC integrations, making it easy to scale across a diverse fleet of equipment.