Automated Order Schedules
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, optimizing performance. It identifies and addresses the root cause of problems, rather than responding to hundreds of subsequent alarms.
Operator Interface
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.
Contextualized Production DATA
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.
Rework Tracking
The system tracks the performance and rework percentage across multiple part and line configurations, then 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.
ERP Sync
Lastly, the system executes transactions against various ERP systems that validate customer and order shipment data. Staff is able to stay up to date with order fulfillment and see how specific production issues might impact delivery timelines.
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