RYAN BERTRAM


“Nothing in this world can take the place of persistence. Talent will not: nothing is more common than unsuccessful men with talent. Genius will not; unrewarded genius is almost a proverb. Education will not: the world is full of educated derelicts. Persistence and determination alone are omnipotent." -Calvin Coolidge

After a 12 year-old Ryan visited the Corvette factory in Bowling Green, Kentucky, he knew he wanted to part of how America makes things. With continued interest in the art and science of manufacturing, Ryan pursued his Bachelors in International Business at Calvin College. After graduating, he realized his dream of working with manufacturing by holding client relations positions throughout the manufacturing industry. At Malisko, Ryan enjoys bringing together the right people for the right job to tackle complex projects, and helping to bring the total solution to the client's plant floor.

Personal Passion
He likes spending time with his family and helping his children to blaze their own trail.

Dream Job
Build houses for Habitat for Humanity

Interesting Fact
He secretly likes the handy-man "fix-it" list his wife gives him every weekend. (Shhh! don't tell her that though!)

CARRIE LEINICKE


"Do not worry about your difficulties in mathematics; I can assure you that mine are still greater" - Albert Einstein

Numbers have always come easy for Carrie. With her natural ability and interest in numbers, Carrie achieved her Master of Science in Accounting from Fontbonne University and then her Master of Business Administration from Webster University. Joining the Malisko Team in 2019, Carrie is very customer service focused and being committed to finding answers for clients. She's passionate about providing accurate financials and forecasting to support high-level business decisions and strategy.

Personal Passion
Being outdoors as often as her schedule allows.

Hobbies
Camping/Traveling with her Siberian Husky, Sailing at Carlyle Lake, and antiquing mid-century/art-deco items.

DAN HARDER




TBD

Personal Passion
TBD

Hobbies
TBD

CASE STUDY

GLOBAL CPG MANUFACTURER TAPS MALISKO TO BE MASTER AUTOMATION INTEGRATOR TO ACHIEVE HIGH OEE FOR NEW US PRODUCTION LINE

GLOBAL CPG MANUFACTURER TAPS MALISKO TO BE MASTER AUTOMATION INTEGRATOR TO ACHIEVE HIGH OEE FOR NEW US PRODUCTION LINE

Background

A global consumer products manufacturer made the business case to install a new production / packaging line to increase capacity. The CPG manufacturer wanted the new line to achieve, then maintain, a high Overall Equipment Effectiveness (OEE) to meet production demands. Malisko was asked to be the Lead Automation Integrator for the new line and develop a fully integrated line control with various OEM equipment.

Objectives

  • Achieve a high OEE line performance and optimization to meet aggressive production goals.
  • Respond instantly to changes in performance effectiveness
  • Connect the controllers of all machines together on a common network to exchange data
  • Enable upstream and downstream machine communication.
  • Institute a standard inter-processor communications schema and structure for the OEM controls engineers to follow.
  • Provide consistency in the data structures and performance-related nomenclature among the OEM controllers for line performance.
  • Adhere to the project’s budget and aggressive schedule.

CHALLENGES

  • The “COVID-19 Effect”
  • Collaboration had to be mostly “remote”
  • Subcontractors from other countries had to hire 2nd and 3rd party resources to communicate and work with Malisko, the client and the other OEMs.
  • Multiple language translations
  • Communication among international OEMs.
  • Tying together different machine types and working with different OEMs
  • Very tight schedule required constant coordination with OEMs
  • Constantly updating client with status of OEE data implementation.
  • Connections to devices that were not natively speaking to each other
  • Some machine controllers were not equipped to talk via ethernet
  • Weighers and printers not configured for ethernet communications.

SOLUTIONS

  • Establish clear and effective communications with the control engineers of each OEM supplier.
  • Maintain a regular cadence of meetings among the OEM engineers/programmers.
  • Tied together the various OEM controller systems into a “Head PLC” / “Line Control PLC” configuration.
  • Enabled machine performance optimization via machine-to-machine communications based on the established standard schema and data structure.
  • Made all logical connections to the “Head” ControlLogix.
  • Data aggregation of all work cell data to a single point for MES and OEE software platforms.
  • Facilitated project and production management alignment and coordination
  • Extension of the customer’s project team
  • Working with operators, supervisors and leadership
  • Expanded project scope during on-site startup and commissioning as requested by the client:
  • We weren’t just on the floor programming controllers
  • We were coordinating with all the OEMs and filtering their requests to the client
  • We served as the primary conduit for communication and coordination
  • Extensive on-site testing and information analysis to verify accuracy and reliability of OEE calculations

RESULTS

  • Increase efficiency and productivity on the plant floor.
  • Project scope, schedule and budget were accomplished.
  • Successfully connected all work cells on one line.
  • Successfully created dashboards and reported line OEE.
  • Client has selected Malisko to expand the implementation to the other lines in the facility.

LEARN MORE

Want to learn more about this project or how we can help you with your manufacturing challenges? Simply fill out the form below and someone from the Malisko team will reach out to you shortly.

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