Manufacturing and Machine Builders: Manufacturing, None

Sussex IM

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Sussex, Wisconsin, United States

Supercell Assembly Machine

Challenges

  • Aging monitoring system - Their original GENESIS32 system from 2002 was outdated and couldn't meet modern manufacturing needs
  • Inefficient alarm response - Technicians had unanswered questions about machine alarms, leading to multiple trips and wasted time
  • Manual data errors - Human errors occurred when configuring production data into Excel spreadsheets, affecting accuracy

Results

  • Faster response times - Technicians now get critical alarm info upfront, and can bring right tools on the first visit, reducing downtime
  • Enhanced visibility - Real-time monitoring with advanced graphics gives "eye on manufacturing floor" for better control and decisions
  • Data-driven insights - Automated logging eliminates manual errors, provides metrics for profitability and asset performance analysis
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“GENESIS has been one of the most powerful tools we have acquired to set us apart from other manufacturers. It has become a showpiece here, but the best part is all the fun I get to have developing the system. GENESIS’ ease of use makes all that possible.”

— Nick Rohrig, Manufacturing Engineer & Engineer responsible for Sussex IM’s GENESIS system | SUSSEX IM

About Sussex IM

Sussex IM, Inc. (SIM) is a leading custom injection molding company headquartered in Sussex, Wisconsin, and has been providing essential supply services to some of the world’s biggest brands for over four decades. Specializing in mid- to high-volume production, the company operates state-of-the-art facilities equipped for automated assemblies, precision molding, and advanced decorating techniques.

SIM serves a diverse range of industries, including consumer goods, healthcare, and industrial products, and holds multiple quality and safety certifications. Known for its turnkey approach, SIM delivers innovative, end-to-end manufacturing solutions that help customers bring high-quality products to market efficiently and cost-effectively.

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“GENESIS has been one of the most powerful tools we have acquired to set us apart from other manufacturers. It has become a showpiece here, but the best part is all the fun I get to have developing the system. GENESIS’ ease of use makes all that possible.”

— Nick Rohrig, Manufacturing Engineer & Engineer responsible for Sussex IM’s GENESIS system | SUSSEX IM
Phase 1 Plant Monitor Phase 1 Plant Monitor

Project Summary

To improve their manufacturing processes and stay ahead of competitors, Sussex IM selected the GENESIS64 automation and digitalization software from Mitsubishi Electric Iconics Digital Solutions’ (MEIDS) . SIM exclusively uses Mitsubishi Electric PLCs, so GENESIS was the logical choice for the automation software.

The company first implemented GENESIS32™ in 2002 as a data monitoring tool to:

  • Observe all machines in operation and display metrics such as cycle time and cycle count
  • Log every shift’s machine alarms and other statistics

As the system began to show its age, SIM upgraded to GENESIS64™, implementing the new system in four phases (approximately two months each):

  1. Replace the bell system – Added numbered lights in the plants tied to switches so operators could call for stock handlers or technicians
  2. Add large display TVs – Installed screens throughout the plants to show in detail which machines needed attention
  3. Log bells and link to variance reports – Captured bell events and attached metrics to variance reports to guide technicians’ continuous improvement efforts
  4. Asset management – Introduced capabilities to track and manage equipment assets
Phase 1 Plant Monitor Phase 1 Plant Monitor

Software Deployed

  • GENESIS64™ web-based real-time HMI/SCADA suite with WebHMI™
  • AssetWorX™
  • AlarmWorX™64 Mulitmedia OPC alarm
Fork Lift Maintenance Tracker Fork Lift Maintenance Tracker

Realized Benefits

According to Sussex IM, one of the main benefits of using Mitsubishi Electric Iconics Digital Solutions software was the improvement in response time and accuracy. Before installing GENESIS64, there were many unanswered questions about when an alarm would sound on a machine. With this platform, the operations team now:

  • Receives all critical alarm information upfront
  • Pinpoints issues more efficiently
  • Arrives equipped with the right tools and equipment for a first-visit repair

Sussex IM also reported additional key benefits of GENESIS, including:

  • Increased precision and advanced graphics capability – providing an “eye on the manufacturing and production floor” with real-time visibility, control, and monitoring
  • Comprehensive problem and metric logging – capturing details on which jobs and products require attention, supporting data-driven production decisions that improve profitability
  • Insight into asset health and performance – enabling proactive maintenance and operational planning
  • Error-free data capture – eliminating human errors from manual spreadsheet entry by automatically logging all production data

GENESIS64 has become a powerful operational tool for Sussex IM, creating efficiencies that result in increased savings and profitability. It is fully integrated into everyday operations at the company’s manufacturing headquarters and will be deployed at a second, expanding facility. To further support the maintenance department, a Mitsubishi Electric Iconics Digital Solutions asset manager has been introduced to:

  • Track and report the status of the company’s indoor vehicles
  • Assist maintenance in communicating and managing repairs
Fork Lift Maintenance Tracker Fork Lift Maintenance Tracker

Conclusion

Sussex IM’s partnership with Mitsubishi Electric Iconics Digital Solutions has allowed them to improve their manufacturing processes, reduce human error, and make data-driven decisions. With its expanding operations, the upgraded GENESIS system has given Sussex IM a competitive advantage and has become a showpiece for the company.

The ease of use and development possibilities of the system have given Sussex IM’s manufacturing engineer, Nick Rohrig, the opportunity to have fun developing the system. The company views GENESIS as a capability tool that allows them to increase profitability and work efficiencies.

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