Digital Transformation: Fairview Mill’s Journey to Data-Driven Manufacturing

In 2024 Fairview Mills had a strategic goal to begin their digital transformation journey to ease the use of their plant-level systems, digitize the paper-based processes, and connect data across multiple locations for faster decision making.

MES Project Goals

• Provide Real-Time, user-friendly data for the whole team
• Data Centralization
• Paperless Plant Floor
• Make data-based decisions on the floor
   

NorthWind designed and implemented an MES solution that digitized their production workflows, automated data collection, and provided real-time visibility into operations. The system was built on the Ignition platform using the Perspective module, creating a centralized source of truth for production data and eliminating paper-based processes.

Our Approach

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NorthWind began with a thorough assessment of Fairview Mills' operations, working closely with operators, supervisors, and management to understand their specific challenges and requirements. The implementation team conducted extensive user interviews to identify pain points and opportunities for improvement.
 

The project followed a phased approach, with weekly feedback sessions to ensure the system met the user's needs. NorthWind's team worked one on one with Fairview's operators and supervisors to ensure adoption and provide training on the new system.

The MES implementation included several key components:

Customized Dashboards for Different User Roles

• Operator dashboards showing current production status, upcoming work orders, and required forms
• Supervisor dashboards providing comprehensive visibility into all production areas
• Management dashboards with efficiency metrics and production performance data
   

Digital Form Builder
NorthWind developed a flexible form builder that allowed Fairview to convert their 25-30 daily paper forms into digital formats. The system includes:
 

• Automated form triggers based on time or production events
• Digital signature capabilities for quality verification
• Searchable form history for easy retrieval during audits
• User-friendly interface allowing Fairview staff to create and modify forms without developer assistance

Real-Time Production Monitoring

• Custom efficiency tracking tailored to Fairview's specific metrics
• Production status visualization across all manufacturing operations
  

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• Automated downtime tracking and reporting
• Integration with existing control systems

Enhanced Communication Tools

• Digital user notes replacing handwritten notes between shifts
• Centralized communication for production issues and status updates
• Visibility of customer specifications and order comments for operators
   

Process Setting Management

• Digital 'cheat sheets' for machine settings by product
• Recommended values for operators to reference
• Consistent process parameters across shifts

The Impact

• Eliminated 15+ daily paper forms, significantly reducing administrative burden and improving data accuracy
• Reduced production reporting time by 45-60 minutes per shift for supervisors through automated data collection and reporting
• Enhanced quality control with digital verification and improved process consistency
• Improved shift-to-shift communication through digital user notes and centralized information
• Streamlined audit processes by making documentation instantly searchable and accessible
• Increased visibility into production metrics allowing for real-time decision making rather than relying on day-old data
• Enabled real-time decision making rather than relying on day-old data, allowing management to respond immediately to production issues and opportunities
• Created a foundation for future digital initiatives including ERP integration and advanced analytics

Future Outlook

With the successful implementation of their MES foundation at the Fairview Kansas facility, Fairview Mills is now positioned for the next phase of their digital transformation journey.
 

1. Integration with their ERP system for seamless data flow
2. Expansion of the MES to additional production facilities
3. Further automation and AI for scheduling processes
    

Fairview Mills has expressed extreme satisfaction with MES solution NorthWind delivered. 'The MES implementation has fundamentally changed how we approach manufacturing at Fairview Mills,' stated Darrin Hermesch, Director of Operations. 'We're now making decisions based on real-time data rather than gut feel, and our operators have the information they need at their fingertips. This digital foundation positions us for continued growth and efficiency improvements in the future.'

Learn more about NorthWind's MES Solutions or reach out to schedule a walk through of a system.

Source: NorthWind