Automotive Supplier Manufacturing
Understanding Automotive Supplier Manufacturing Business Challenges
Consider this: Your operating costs are the same, regardless of fluctuations in throughput (and therefore your profits). So every minute of production lost due to a true constraint is equal to the cost of a minute of running the entire line or plant. And every minute gained is a true contribution to your bottom line.
"Activplant allowed us to analyze cycle times and workflow performance at each assembly station, uncover constraints, and remove bottlenecks. This had a major impact on our throughput. Overall the Activplant system has helped us get the line up and running, debugged, and provides ongoing performance improvement. The impact on our business has been dramatic."
- Unit Manager
Tier 1 Supplier
Throughput Analyzer™ can put those lost minutes of production back into your shift. What would a 5% improvement equaling an extra 21 minutes mean to your facility? In a continuous low bottling operation, that can mean thousands of more units equaling millions of dollars.
"Collected correctly, data turned into information aids us in our 'Genchi Gembutsu' or Go and See activity to grasp the situation. Grasping the Situation is one of the first things that we are taught to do at Toyota, as it is part of the Toyota Way. The Activplant Performance Management System enables our Go and See Process."
- Parker Shannon
Project Manager
If you have to identify an additional 5% in throughput improvements would you know where to look?
Activplant Customers know where to look!
While automotive manufacturing suppliers range from local operations to
multinational organizations with facilities and distribution across the globe,
their challenges remain the same. How do you lower unit costs per piece while
increasing overall quality while utilizing fewer resources and less capital dollars.
Many manufacturers are told by software companies that the answers to
improving your operations are better OEE metrics and downtime reports.
This thinking does not go far enough to make a significant impact on your
bottom line. Activplant has the only solution that can identify your chronic
constraints and allow your team to focus their efforts on the true problem
areas to increase the overall throughput on your entire system. We understand
the automotive manufacturing industry, and we can help you turn these
challenges into a competitive advantage. With Throughput Analyzer's
clear focus on improving your business, you have a choice to continue
to experience a 3% to 5% improvement with your existing continuous
improvement team, or you can show a 15%- 25% improvement with a
deliberate intention to focus on the chronic constraints using Activplant
Throughput Analyzer. In an average sized automotive manufacturing facility,
an increase in production throughput could result in over a $1.2 million annual
savings. Now you can take that result to the bank. Don't wait to make your
deposit, with Throughput Analyzer's rapid and repeatable deployment of
less than 14 weeks, you could be cashing in the savings in as little as about 3
months.
Activplant's Throughput Analyzer can transform the raw data coming from your line into actionable information. A Balance Map (shown here) is updated in real time using intuitive color coding, allowing you to identify production constraints at a glance.
Delivering the Solution
The challenge has always been how to isolate and identify the most inefficient
area on the line that impedes or chronically disrupts product low. The problem
may lie in people, material, or machines providing components, which can
simultaneously shutdown multiple other machines on that line making it more
difficult to understand the root cause. Further complicating this process is the
fact that constraints move from hour to hour and shift to shift making it nearly
impossible to identify the chronic constraint in the line.
Activplant's Throughput Analyzer is a proven performance management
application that simplifies the complexities of maximizing your plants
efficiencies. By identifying and prioritizing the chronic disruptors to product
low, otherwise known as the constraints, Throughput Analyzer empowers
plant personnel to focus on the issues that will result in the largest gains in
throughput – and enables management to make informed decisions that will
positively impact the bottom line.
"Throughput Analyzer captures data from every manufacturing line, giving us a direct view of how each line is running. If there's a slowdown, we can see if it's caused by downtime, delays in cycle time, inadequate product flow or any other root cause."
- Ted Hansen
Occupant Safety Systems
Now Automotive Manufacturers have a solution to respond to the everyday
challenges faced in this industry. By eliminating the waste caused by constraints,
getting more parts out the door with fewer resources is no longer a challenge
but a reality. The Throughput Analyzer will sorts though all the noise and
account for every second of production with the touch of a button. Whether
the root cause is a changeover issue, speed loss, downtime loss, or human
involvement, the Throughput Analyzer points you to the true constraints. For
example the Throughput Analyzer drives part and component cost down by
enabling the correction of the #1 problem limiting throughput and overall line
velocity. Now you can spend your day fixing the problems, not trying to figure
out where they are.
It's About Time
At Activplant, it's about time. Our Throughput Analyzer application is defined by
its ability to identify lost minutes of production within a line, plant or enterprise
and then provides you with the knowledge to put those minutes back into your
day. Identifying and regaining those lost minutes of production may mean 100%
delivery rate on your customer's orders, unlocking hidden capacity during times
of high seasonal demand or reducing unit/case cost to the lowest possible level.
See what Throughput Analyzer can do for you
Watch a product demo now or request additional information.
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