Eastman Kodak boosts efficiency through upgrade
Eastman Kodak is using Rockwell Automation technology and training to reduce downtime and improve efficiency. The training aspect is key, as it eases the technology transition, minimises learning curves and improves the technology skills background.
For more than a century, the name Kodak has been synonymous with photography. Today’s Eastman Kodak Company is still known for photography, but also for its ability to offer high-tech products and imaging devices used in a variety of leisure, medical, business, entertainment and scientific applications. The company is increasingly using technology to combine images and information, creating the potential to profoundly change how people and businesses communicate.
Like many companies, Eastman Kodak places a strong emphasis on maximising uptime and throughput to reduce costs and increase efficiency. As part of this effort, the company’s film-imaging division, Kodak Colorado, opted two years ago to upgrade the automation controllers used on several of its manufacturing lines at its facility in Windsor.
“Eastman Kodak eased the transition to new technology with a training program, all of which has resulted in a 10% reduction in downtime.” |
The upgraded automation controllers enable Eastman Kodak to create high quality X-ray film at lower cost |
The upgrade, which primarily impacted lines manufacturing X-ray and medical-laser film, was designed to take advantage of new technology that would improve production efficiency, creating high-quality X-ray film at a lower cost. Kodak Colorado upgraded several lines from Allen-Bradley® PLC- 5 controllers to Allen-Bradley ControlLogix controllers to meet increased production demands, take advantage of new technology features and transition to more advanced equipment.
Needing to ensure maximum uptime, the company wanted to make sure its engineering and operations staff would be adequately trained and would fully understand how to successfully transition old systems to new technology and equipment.
As Kodak Colorado already had a large installed base of Allen-Bradley products and had previously engaged Rockwell Automation to provide customer support across multiple Kodak sites, the company was confident that Rockwell Automation could provide the training necessary to realize maximum return on investment. The company immediately saw how product training could support its current and future needs.
The training programs were customised and designed to meet the individual needs of Kodak Colorado’s staff in a way that maximised learning while optimising the company’s training investment. The first step was an Integrated Performance Assessment (IPA) to identify performance inhibitors and lay the groundwork for measurable performance improvement. The IPA went beyond traditional coursework or skills training to examine a multitude of issues affecting a company’s workforce and the adoption of the new technology. The IPA discovered that employees need categories: engineering and maintenance. The engineers required more intimate knowledge of the technology, while the maintenance group required a higher level of troubleshooting knowledge.
Rockwell Automation suggested that Kodak Colorado implement a tiered training course, including an engineering-level and a mechanic-level class, designed to help Kodak Colorado employees with diverse skill sets adapt more quickly to the new control technology.
Training programs were customised to meet Eastman Kodak's needs, maximising learning whilst optimising the training investment |
Six months before installation of Kodak Colorado’s new equipment, Rockwell Automation conducted a preliminary training session to help engineers and mechanics learn the technology prior to actual installation, when there would be more pressure and fewer margins for error. An advanced class was held several months after the new equipment and technology was installed, providing the critical link needed to transfer knowledge from the classroom directly to the plant floor.
Reduced downtime
Upon completion of the training program, Kodak Colorado reported a reduction in recovery time associated with the new equipment resulting in a 10% reduction of downtime. The new skills gained by engineers and mechanics in the classes have helped them better troubleshoot and more quickly resolve problems because they better understand the equipment and technology. With increased speed and accuracy in responding to problems, Kodak Colorado has been able to reduce its mean time to recover. More importantly, the combination of increased productivity and reduced downtime have allowed Kodak Colorado to focus on more important priorities, such as producing high-quality imaging film and improving business profitability. Kodak’s process engineers are happy with the decision and the outcome.
Using ControlLogix, Kodak Colorado engineers can utilise the common programming environment to shorten design time, enlist one controller for multiple tasks, and mix processors, networks and I/O without restrictions — all
in the interest of simplifying the manufacturing process for a complex product.
By collaborating with Rockwell Automation on training, Kodak Colorado found it could improve the performance of plant equipment and employees and drive efficiency throughout the manufacturing process. The company wanted to build on the success of the training program and is currently implementing additional programs to assist in increasing production and reducing downtime.
“We continue to use Allen-Bradley products on our lines because they are easy to understand and provide us with the performance options we need,” concluded Kodak Colorado’s lead process engineer. “When we decided to look for an outside training program, Rockwell Automation was the obvious choice. And we are extremely pleased with the job our training representative did in helping us to learn and understand the new technology.”
For more information, please e-mail us at: info_at@ra.rockwell.com with ref: Kodak
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