The Activplant Performance Management System for Frame Assembly 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 Door System 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

Frame Assembly Plant Challenges

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

• ensuring the proper build to sequence mix and component sequencing to final assembly
• minimizing model changeover times
• maximizing line throughput
• maintaining weld quality and integrity
• reducing line faults and downtime
• controlling high costs per hour to operate

Sample Analytical Reports and Tools

Key performance indicators for a station OP40 giving a snapshot view of how that station is performing.

Takt Time Report

The Takt Time report is used to isolate constraints on the line. Both OP10 and OP40 on this line are averaging over the target 40 second cycle time and need to be investigated to find the cause using the Activplant Performance Management System analytical tools.

How Activplant Performance Management System Solves Frame Assembly Challenges

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

Improving throughput (Best Practice #2 – Turn Capacity on With Demand ) – Activplant Performance Management System collects reliable capacity data by operation including actual time for setups and cycle time by part number. This data is critical for accurate capacity planning and effective production scheduling.

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, machine cycles and other critical usage metrics. then 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.

Minimizing process variation (Best Practice #5 – Six Sigma Process Control ): Activplant Performance Management System gathers critical process metrics for each station and component 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. Each component and its process metrics is tracked through serial number and source/lot code to ensure traceability.

Eliminating uptime losses from blocked, starved or waiting conditions (Best Practice #6 – Operate with Real-time Intelligence ): Activplant Performance Management System collects uptime loss times and provides analytical reports, tools and methods to quickly identify assets or lines that are suffering from uptime losses and find what is causing this uptime loss.

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, process metrics, job loss causes, WIP inventory levels 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

• Improve productivity
• Reduce scrap and rework expense
• Higher Return on Assets%
• Reduce overtime variance
• Minimize downtime %