The Activplant Performance Management System for Body Weld plants is the only comprehensive configurable system that delivers world class manufacturing metrics on production results against targets and tells you where, when, how and why production is being lost. It is specifically designed to deliver actionable manufacturing intelligence for Body Weld plants.

But beyond that having gathered, reported and generated an analysis of production results and losses across the entire plant it provides an actionable roadmap based on world class manufacturing best practices on how to use this intelligence to eliminate the losses.

The system is based on almost a decade of manufacturing intelligence experience, lean manufacturing principles and the best practices of leading manufacturing companies.

The Activplant Performance Management System is a proven solution consisting of:

• the market leading EMI software platform Activplant,
• a set of pre-configured profiles that deliver a pre-defined data collection, reports and analysis templates designed for your specific type of plant,
• an operations methodology that will help you drive results,
• an implementation methodology to accelerate implementation
• implementations services to ensure success

Body Weld Challenges

As the one responsible for ensuring production, cost, quality and delivery targets you have to deal with:

• removing line constraints and increasing throughput
• eliminating unscheduled downtime
• improving weld process integrity
• ensuring preventive, predictive and manual maintenance attention on robot weld heads
• managing high overhead and cost per hour of operation

Sample Analytical Reports and Tools

MTBF and MTTR Trend Chart - a key maintenance metric monitored by Activplant Performance Management System

Real-time Manufacturing Intelligence

Real-Time Manufacturing Intelligence display in Activplant Performance Management System. Part counts will get updated every 2 minutes on the screen, while states, fault/alarms, process variables and cycle time can be displayed in real-time

How Activplant Performance Management System Solves Body Weld Challenges

Based on the Activplant Operations Methodology six best practices, the Activplant Performance Management System solves the problems facing Body Weld plants by:

Reducing unscheduled downtime (Best Practice #3 – Assure Availability): Activplant Performance Management System tracks downtime event duration and occurrences for every asset and delivers a set of analytical reports tools and methods that can quickly identify offending assets or lines and the causes of downtime.

Applying predictive and preventive methods to minimize downtime (Best Practice #4 – Predictive and Preventive Maintenance): Activplant Performance Management system collects production counts, welds and machine cycles and can trigger appropriate proactive countermeasures based on these metrics. With Activplant’s optional Enterprise Gateway module you can feed this critical information to corporate business systems, such as CMMS, ERP and BI systems.

Ensuring weld process integrity (Best Practice #5 – Six Sigma Process Control): Activplant Performance Management System collects critical process metrics for each weld to help ensure each meets specification. Activplant Performance Management System also provides analytical reports, tools and methods that can quickly identify offending assets or lines and the causes of rejects or quality issues.

Delivering real-time Manufacturing Intelligence (Best Practice #6 – Operate with Real-time Intelligence): Activplant Performance Management System delivers the real-time manufacturing intelligence such as JPH, machine states, weld process metrics, job loss causes and production targets that operations management needs to be in in-touch with all four corners of their plant at all times.

Activplant Performance Management System Key Performance Indicators and Value Drivers

• Increase Uptime %
• Higher JPH
• Improve capacity utilization (ROA%)
• Reduced scrap and rework
• Reduced overtime variance