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OEM's Tier 1 and 2 suppliers are continually striving for greater consistency in Quality, Cost and Delivery.
JIT and sequenced delivery has forced the removal of waste but with high mix variations and equipment availability affecting performance and operating margins it is now critical to have visibility of the current production status, combined with urgency to rectify issues and generate real root cause countermeasures to maintain and grow business.
PlantRun gives system visibility, applying discipline and urgency to react and kill problems at their root cause. PlantRun linked to the facilties Value Stream Map gives accurate data in real-time to build a foundation for continuous improvement activity. True operations excellence is only delivered from a solid foundation and Maintenance and Production pesonnel working with a common purpose. PlantRun enables this by minimising inter-department conflict with accurate information on the true causes of downtime.
- Visualisation of system and bottleneck performance
- Equipment availability improvement
- Performance measurement
- Real performance benchmarks of operator and equipment
- Cross functional process ownership
- Component cost validation
- Increased capability
Futaba Tenneco UK is a joint venture operation of two of the worlds leading automotive suppliers, set up to supply UK & European car plants with pressed and welded sub assemblies.
The company site in Burnley, UK has benefited from a major investment program since the merger of the two companies and operates 115 state of the art robot welding/assembly units. As well as a suite of presses ranging up to 2,500 tonne to provide the most capable and efficient pressing service available.
A PlantRun system monitors the machines which are configured as 72 work cells providing machine utilisation reporting and analysis. The system allows the company to track production efficiency and helps it meet the demanding JIT requirements of the automotive industry.
The system integrates with the site public address system to automate call outs for re-stocking, engineer assistance etc. Large screens have also been installed in the production area that display live production performance data that helps to inform and motivate staff.
Futaba-Tenneco is a Toyota award winning supplier providing varied pressed and welded components such as roof pillars, centre pillars, roof rails etc direct to the production line in Derbyshire.