实例探究 > Chassis Systems Ltd Enhances Production Efficiency with Lighthouse Systems Shopfloor-Online

Chassis Systems Ltd Enhances Production Efficiency with Lighthouse Systems Shopfloor-Online

公司规模

Large Corporate

地区

Europe

国家

United Kingdom

产品

Lighthouse Systems Shopfloor-Online

技术栈

Wireless Network
Rugged Tablet PCs

实施规模

Enterprise-wide Deployment

影响指标

Productivity Improvements
Customer Satisfaction

技术

功能应用 - 制造执行系统 (MES)
网络与连接 - 无线局域网

适用行业

汽车

适用功能

质量保证
流程制造

用例

机器状态监测
预测性维护
远程资产管理

服务

系统集成
软件设计与工程服务

关于客户

Chassis Systems Ltd (CSL) is a joint venture between Dana and GKN, formed to produce chassis structures for Land Rover's Discovery and Range Rover Sport models. As a high-volume producer of complex, high-value parts, CSL places a strong emphasis on quality assurance. The company operates in the automotive industry, focusing on precision manufacturing processes that involve over 200 parts and more than 700 welds per chassis. Ensuring the quality of each product is crucial, and CSL has implemented procedures to measure and record inspection data across the production line. Historically, much of this data recording was done manually, which was time-consuming and prone to errors. CSL sought to improve efficiency, accuracy, and quality in its production processes by leveraging advanced technology solutions.

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挑战

Chassis Systems Ltd (CSL) faced challenges in ensuring the quality of chassis structures for Land Rover's Discovery and Range Rover Sport models. The production process involved over 200 parts and more than 700 welds, requiring precise quality control. Historically, data recording was manual, making analysis cumbersome and time-consuming. CSL needed a solution to improve data visibility, automate processes, and increase inspection throughput. The manual system was inefficient, requiring operators to generate PDF documents for alerts, which consumed time and resources.

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解决方案

CSL implemented Lighthouse Systems Shopfloor-Online to enhance data visibility and automate processes. The system's modular design allowed for future functionality additions, such as downtime analysis and maintenance management. Phase one focused on improving CMM data visibility, freeing up engineers' time and increasing inspection throughput by 50%. The system automated alerts for out-of-specification readings, eliminating manual PDF document generation. Phase two involved providing patrol inspectors with rugged tablet PCs connected to Shopfloor-Online over a wireless network. This allowed real-time reporting of visual inspections, replacing the manual catalog approach. Inspectors could now log checks and faults immediately, reducing training requirements and improving accuracy. Phase three ensured end-of-line quality checks, with faults input into Shopfloor-Online for detailed reporting and containment until repairs were made. The system provided a complete audit trail, enabling fault frequency and corrective action reporting.

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运营影响

The implementation of Shopfloor-Online automated many manual processes, freeing up operator time and reducing the need for manual data entry.
CMM operators experienced a 50% increase in sampling throughput, allowing for more products to be inspected each day.
Patrol inspectors benefited from real-time data availability, enabling immediate reporting of visual checks and faults, which improved accuracy and reduced training requirements.
The system provided a complete audit trail of the chassis production process, allowing for detailed reporting on fault frequency and corrective actions.
The automated alerts for out-of-specification readings pre-empted potential problems, allowing operators and engineers to take corrective action before faults occurred.

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数量效益

Sampling throughput increased by approximately 50% due to the new system.
Real-time reporting reduced the time required for end-of-shift inspections and data entry.

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