How to reduce the human factor in production?

The Customer

The company is a manufacturer of trucks used in more than 80 countries around the world. For more than 50 years of the company's existence, it has produced more than 2.25 million cars and about 2.85 million engines.

The problem

The Customer has automated the processes of design and technological preparation of the production, implemented an ERP system, but the conveyor production still worked “in manual mode”:

  • the orders, transferred to production, are printed on paper;
  • no detailed operational planning of production;
  • no prompt response to changes in the product specification;
  • no requirements for the production nomenclature;
  • no monitoring of production capacity;
  • no quality control of each assembly operation and the quality of the finished product as a whole.

The tasks:

  • Control the production planning based on the received orders.
  • Provide personnel and equipment with the information in electronic form, necessary to start the production process, based on the technological process.
  • Gather information about the production process based on sensor measurements, equipment readings, personnel actions.
  • Ensure control over the product’s quality parameters.
  • Identify and analyze the causes and sources of defects, provide transparent tracing from the finished product to the executor of a specific assembly operation, the detail/part, placed on the product, its manufacturer, and supplier.
  • Ensure support for industry standards and legal requirements of manufactured products.
The solution
  • The Siemens Opcenter ExDs MES system was chosen to meet the needs of the Customer.
  • The system was integrated with PLM-system Siemens Teamcenter, ERP-system SAP.
  • The system was integrated with the equipment installed on the conveyor; it controlled and recorded the parameters of its operation.
The result
  • The transfer of orders to production now takes into account a load of equipment and, as a result, the downtime is minimized.
  • Each worker on the conveyor at any time knows what operations must be performed to assemble the incoming order, therefore labor costs are minimized.
  • It is impossible to install the “wrong” part, as well as to forget to install the required one: the system will not allow the line to move on until all operations are completed, thus reducing the human factor.
  • Each finished product is given an electronic passport, which includes an accurate list of installed parts, their manufacturers, assembly operations performed, and their parameters (for example, the efforts to tighten the nuts), therefore, the service history begins with the production.
  • Accurate prediction of the production schedule, and as a result - improved quality of production management as a whole.
  • Construction of transparent process management system.
  • Improved product quality.
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