The Activplant Performance Management System for Powertrain and Engine 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 Powertrain and Engine 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

Powertrain and Engine Plant Challenges

As the one responsible for ensuring production, cost, quality and delivery targets on a Powertrain and Engine assembly line you have to deal with:

• excess process variation
• warranty exposure and ensuring part and component traceability
• eliminating unscheduled downtime

If you are responsible for a machine line you have to manage:

• sequencing components into final assembly to minimize final assembly stoppages
• ensuring component quality
• maximizing line uptime and line balance
• lot and batch control
• tool life

Sample Analytical Reports and Tools

Pareto chart of machine faults by duration indicates which stations are down the most and this becomes the start of the analysis of determining fault causes.

Birth History Report

This Birth History Report provides a record of every component, including all the appropriate process metrics.

How Activplant Performance Management System Solves Powertrain and Engine Challenges

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

Improving throughput (Best Practice #2 – Turn Capacity on With Demand ) – Activplant Performance Management System gathers 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 collects downtime duration and occurrences for every asset and delivers a set of analytical reports and tools 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. You can even in with Activplant’s Enterprise Gateway 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

• Increase jobs per hour
• Reduced scrap and rework
• Improve downtime %
• Warranty cost avoidance
• Minimize overtime variance