Market Change Results in Lost Sales Due to “Inflexible” Fixed Tooling Assembly Systems
公司规模
Large Corporate
产品
- eFlex Assembly
技术栈
- MES level
- PLC logic
实施规模
- Enterprise-wide Deployment
影响指标
- Productivity Improvements
- Cost Savings
- Innovation Output
技术
- 功能应用 - 制造执行系统 (MES)
适用行业
- 汽车
适用功能
- 离散制造
- 质量保证
用例
- 自动化制造系统
- 预测性维护
服务
- 系统集成
- 软件设计与工程服务
关于客户
The customer in this case study is a global automotive manufacturer. They had major investments in their highly automated fixed tooling for 4-and 6-cylinder engine assembly lines. Both lines met their market requirements reliably for many years, with the 6-cylinder being higher in demand. However, a sudden spike in gas prices influenced buyer behaviors and resulted in a higher demand for the 4-cylinder engines. As a result, the demands for 6-cylinder engines dropped and the market demand for 4-cylinder sharply increased overnight. This sudden shift in market demand exposed the inflexibility of the manufacturer's assembly lines.
挑战
A global automotive manufacturer was facing a sudden shift in market demand due to changes in fuel prices. The demand for 4-cylinder engines increased overnight, while the demand for 6-cylinder engines dropped. The manufacturer's assembly lines, which were highly automated and fixed for 4-and 6-cylinder engine assembly, were not flexible enough to adapt to this change. The 4-cylinder line was running around the clock but could not increase its capacity beyond its original design capabilities. The 6-cylinder line was meeting production requirements by 10 am and sitting idle for the rest of the day. This inflexibility resulted in lost sales opportunities.
解决方案
To address the inflexibility of their assembly lines, the global manufacturer standardized their global powertrain operations with the eFlex Assembly architecture. eFlex Assembly is a flexible assembly line optimization solution that includes software, hardware, and reporting tools. It integrates equipment and manpower on the plant floor to create an intelligent manufacturing system that is globally standardized, high quality, and highly flexible for production, maintenance, quality, process, and training. The flexible and modular design, technology, and tools in eFlex Assembly make rebalancing or reconfiguring an assembly line as simple as unplugging and re-plugging the equipment. This “plug-n-play” architecture, with validated standardized processes, drastically reduces changeover time.
运营影响
数量效益
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