We created automated order schedules for each manufacturing site and for individual lines within the site. Schedulers and line supervisors can create their own dynamic sequencing rules based on the characteristics of the order. This means the system can shuffle the order and part flow of manufacturing items to different machine centers to achieve optimal performance.t to identify and solve the root cause of the problem, rather than responding to hundreds of subsequent alarms.
We provided a front-end interface that contains all the info an operator needs at a glance. This includes bills of materials, manufacturing holds, part defects, inspections and work instructions. By recording all this data and tracking its flow, we replaced paper-based operations with a system that can pull up every detail of what happened in an order.
We split and optimized production into time-based slices to ensure each work order would satisfy the required total number of shipped products for the day. The system can identify the 1000s of parts that are required to satisfy multiple customer orders and split them into lots that are tracked and recorded against inventory.
The system tracks the performance and rework percentage across multiple part and line configurations and reports which lines are having the most difficulty reaching performance metrics such as Takt time. Operators can tell what has been produced, where it needs to go, and what reworked parts are ready to be transferred back into production.
