The Activplant Performance Management System for Vehicle 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 Vehicle Assembly 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 enterprise manufacturing intelligence 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
   

Vehicle Assembly Challenges

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

• removing line constraints and increasing throughput
• ensuring the repeatability of design cycle times. You cannot afford to have your lines throughput crippled by over cycle conditions in any station
• reducing the number of defective parts and assembly issues
• minimizing the number of vehicles you have to send to the rework bays – it is a cost you do not need
• keeping your lines from stopping because stations are starved or blocked
• controlling overtime costs, especially when you have to run overtime or extra shifts to meet your production targets

Sample Analytical Reports and Tools

Lost Jobs Chart by Shift shows what was produced each shift and where production was lost

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 Vehicle Assembly Challenges

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

Improving line balance (Best Practice #1 – Streamline process flows to reduce Cycle Time losses ) - Activplant Performance Management System collects detailed breakdowns of every asset’s cycle time and provides a set of analytical reports, tools and methods to help identify problems and streamline the process flow of any discrete manufacturing line. These tools include a TAKT Time chart to quickly identify constraints.

Reduce unscheduled downtime (Best Practice #3 – Assure Availability): Activplant Performance Management System gathers reliable downtime 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.

Minimize scrap, rework and poor quality assemblies (Best Practice #5 – Six Sigma Process Control): Activplant Performance Management System tracks the number of rejects and the reasons for failures, as well as process metrics for each part and assembly. 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.

Eliminate 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.

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

Labor/plant productivity: JPH and Hrs./Vehicle
FTQ% (Rolled throughput yield)
MTBF/MTTR – Mean Time Between Failures and Mean Time To Repair
Reduced scrap and repair bay cost
Reduced overtime variance