The Activplant Performance Management System for Door System 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

Door System Challenges

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

• excess process variation, especially in torque gun tries per hole, screw torque and angle, adhesion/over molding and alignment
• ensuring safety features and proper build sequence to prevents accidents in use
• maintaining source and lot code integrity for warranty purposes
• eliminating unscheduled downtime

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.

Production Summary View

This production summary view provides a detailed summary of production counts, line state times, states and process metrics.

How Activplant Performance Management System Solves Door Systems Challenges

Based on the Activplant Operations Methodology six best practices, the Activplant Performance Management System solves the problems facing Door System 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.

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.

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

• Reduce downtime %
• Warranty cost avoidance through basic traceability
• Reduce scrap and rework
• Reduce rejects at assembly plants