Published: Jan 24, 2025
Reading time: 4 min
Manufacturing companies lose millions each year because of poor tooling management. Production costs related to tooling problems account for up to 20% of total expenses. Honeywell encountered these same issues with tooling lifecycle management and needed better ways to control costs while meeting cycle time requirements in manufacturing facilities.
Digital Transformation Journey
Honeywell embarked on a digital transformation journey to address inefficiencies in its tooling management infrastructure, which directly impacted operational efficiency. A thorough legacy system evaluation revealed key challenges that required immediate attention.
- Inconsistent Tooling Tracking: Tool ownership was difficult to determine.
- Maintenance Challenges: Maintenance schedules were reactive, causing unexpected downtime and operational delays.
- Supplier Collaboration Gaps: Suppliers operated in silos with minimal real-time data sharing, reducing transparency.
- Costly Production Inefficiencies: Poor lifecycle tracking and capacity planning added to the overall expense
Solution Selection Process
After evaluating multiple solutions, our IoT platform emerged as the clear choice for Honeywell. Key factors that influenced their decision included:
- A user-friendly mobile application that facilitated supplier adoption and provided real-time data access.
- Integration capabilities for online and offline tools were critical for managing 50% of the offline tooling fleet.
This platform allowed Honeywell to efficiently manage nearly 4,000 tooling assets across its Building Technologies division.
Implementation Roadmap
Honeywell adopted a phased implementation strategy, starting with a pilot program covering 200 tooling assets distributed across European and American facilities.
The roadmap included the following steps:
- Initial Deployment: Started with five high-volume suppliers.
- Audit Services: Conducted using eMoldino’s audit services to assess inventory.
- Detailed Audits: Focused on critical tools for in-depth evaluations.
- Mobile Application Rollout: Launched to facilitate easy adoption among suppliers.
Early results showed promise. We provided vital support through specialized brackets and housings for sensors. These components ensured optimal performance in high-temperature environments up to 140°C. This technical precision helped maintain sensor integrity and data accuracy in our various manufacturing operations.
Technical Solution Architecture
Honeywell required a robust solution for tooling management, which was addressed through a three-tier system integrating IoT sensors, data management, and advanced analytics.
IoT Sensor Infrastructure
eMoldino’s wireless IoT sensors, with encrypted data transfer and 5-year battery life, were deployed across key manufacturing sites to withstand demanding environments.
Data Integration Framework
A seamless framework connected Honeywell’s SAP system with our platform, processing real-time data from over 2,500 tools across American and European facilities. It also supports online and offline management, including protocols for low-runner tools producing 8,000 units annually.
Quantifiable Benefits
The solution has transformed tooling management, driving significant production efficiency gains. Improved uptime metrics underscore its impact in streamlining operations and boosting output across facilities.
Key Achievements of the Project
The project delivered measurable improvements across multiple facilities, showcasing significant gains in efficiency, cycle time compliance, and ROI for contract optimization:
Plastibell: Achieved a 2.16% efficiency increase and a 5.5% cycle time improvement, supported by high and constant uptime and improved cycle time compliance, resulting in an ROI of $625,647 over 5 months.
Plastiexports: Recorded a 6% efficiency increase and a 23.7% cycle time compliance enhancement, despite variable production volumes and changing uptime conditions, generating an ROI of $161,040 over 5 months.
VT Bulplast: Delivered a 0.2% efficiency increase and a 23.1% cycle time improvement, bolstered by improved and stabilized cycle time compliance and consistently high uptime, yielding an ROI of $154,200 over 10 months.
Wattera: Achieved a 1.83% stabilization in efficiency and a 19.3% enhancement in cycle time, maintaining stable production processes and uptime despite minor deviations, resulting in an ROI of $6,499 over 5 months.
Expansion Plan
Building on their initial success of digitizing 200 tools by 2024, Honeywell plans to scale this digital transformation across multiple business units. By the second quarter of 2025, the company aims to digitize 4,000 toolings, and by the fourth quarter of 2025, reach 8,000 toolings. This growth strategy will focus on:
- Adding 1,300 offline tools in plastics EMA division.
- Growing to 5 additional critical suppliers with high-volume production.
- Rolling out mobile-first solutions that suppliers can use.
- Setting up advanced sensors in new facilities.
Conclusion
Honeywell’s partnership with eMoldino has transformed tooling management, shifting, from manual processes to digital excellence. The solution addressed key tooling tracking, maintenance scheduling, and supplier management challenges, delivering substantial ROI and operational improvements.
Contract Optimization Savings:
- Plastibell: $625,647
- Plastiexports: $161,040
- VT Bulplast: $154,200
- Wattera Mx: $6,499
Beyond immediate gains, 90% of tools now operate within ideal parameters, and 90% supplier adoption of our mobile-first strategy ensures predictive maintenance and production stability. With plans to scale tooling management from 4,000 to 8,000 tools, enhanced analytics, and continuous improvement, Honeywell is well-positioned to sustain manufacturing excellence in a competitive global market.
About the author
eMoldino
eMoldino aims to digitalize, streamline, and transform your manufacturing and supply chain operations. We help global manufacturers who want to drive corporate innovation while maintaining the core values of collaboration and sustainability. Talk with us to learn more →
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