Lucchini RS

Lucchini RS is a leader in the design, production, industrialization and sale of high-tech steel products for numerous industrial sectors, ranging from railway products to forged items made to drawing. The company implements a rigorous Quality Assurance System certified under ISO 9001-2008, IRIS - International Railways Industry Standard, and also has ISO 14001 environmental certification.

As part of the process of continuous improvement and in order to maintain a consistently high standard of quality and optimise production costs, LUCCHINI RS commissioned STAIN to design an MES system for the train wheel production bay. Introduction of STAIN+ suite for controlling production and tracking processes and testing of each individual wheel achieved the following results:

• Full visibility to all authorised users of the status of stocks of each wheel type at all times and search options by series, stage, date, shift, operator and so on.

• Electronic tracking of all the wheels made, by machine, production order, date, shift, operator, result, reworking.

• Complete integration with the SAP/R3 management system and elimination of laborious paperwork by the operator for recording production data and test measurements.

• Centralized server filing of all production, test and stock data trends to allow periodic statistical analysis in view of continuous process optimisation.

• Electronic acquisition and recording of rejects, non-conformities and reworking.

• Acquisition and recording of machine downtimes, with stoppage cause and statistical downtime processing.

• Processing and dissemination of performance, efficiencies and OEE indicators by machine, production order, article and series.

• Automatic acquisition of the results of wheel tests throughout the production cycle.