Powertrain Manufacturing
Understanding Powertrain 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!
The Engines, Transmissions & Powertrain Components manufacturing industry
is at an unprecedented time of change. Manufacturers are driven constantly by
technology and design changes that push for the need to increase automotive
fuel efficiencies. With these ever-increasing product complexities, manufacturers
are still being held to maintain lower product costs.
Many manufacturers are told by software companies that the answers to
improving their 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 increase the overall throughput for your entire system. We understand the
Engines, Transmissions & Powertrain Components industry, and we can help you
turn these challenges into a competitive advantage. With Throughput Analyzer's
clear focus on improving your business, you could expect to experience an
increase of 5% to15% in production throughput like other Activplant customers.
In an average sized Engine, Transmissions & Powertrain Components facility, a
5% increase in production throughput could result in over a $3 million annual
savings. Now that's a result you can take to the bank. But you don't have to
wait to make your deposit, with Throughput Analyzer's rapid and repeatable
deployment of less than 14 weeks, you could be cashing in savings in as little as
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
is that when one machine goes down on the line, it 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 high volume continuous low
environments. 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 Engines, Transmissions & Powertrain Components Manufacturers have
a solution to respond to the everyday challenges faced in this industry. By
eliminating the waste caused by constraints, getting more jobs per hour out the
door with fewer resources is no longer a challenge but a reality. Whether the
constraint is on a block line or head line, the Throughput Analyzer will account
for every second of production and identify with the touch of a button whether
the root cause is a operator issue, speed loss or downtime loss; the Throughput
Analyzer points you to the true constraints. For example, 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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