Digital-enabled performance management
30% efficiency gain
Digital-enabled performance management
Key use cases
ANDRITZ Ritz implements seamless dataflow from CAD/CAM to machine tool controllers
Case example 2 / 9
The solution from Siemens Teamcenter enables ANDRITZ Ritz to transfer project information from manufacturing planning seamlessly to production. On the shop floor, PC workstations are connected to machine controls via a serial interface or Ethernet. Machine operators gain role-specific access to released data. For each job, only the information needed is shown. Depending on the job complexity, simulation data, CAM parts, CAD models, pictures, videos, and work plans may supplement the default information of NC data, shop floor drawings, and tooling sheets.
Due to the direct access to PLM information on the shop floor, the machines’ idle times are significantly reduced, and the operators can effectively minimize variations in quality and manufacturing errors.
Direct access to PLM information on the shop floor
Industrial equipment manufacturer boosts efficiency through “shop floor to top floor” digital enablement
Case example 1 / 9
TATA co-developed an end-to-end visibility solution in two assembly plants of a Swedish industrial tools and equipment manufacturer. The solution created transparency throughout both the inbound and outbound enterprise supply chain.
Custom applications of the solution included integration with ERP, a shop floor control system, and third-party logistics. TATA implemented key functionalities including order management, kitting, electronic Kanban, traceability, torque and test data logging, digital work instructions, barcode printing, and real-time updates via dashboards. The bottom-line results of this connectivity solution were a 30 percent efficiency gain in product planning and a reduction in subassembly WIP time from three days to four hours.
30%
efficiency gain in product planning
Integrated product data model
Integrated product data model
Reduction in idle time
Data-driven OEE optimization
Data-driven OEE optimization
80% OEE increase
Flexible routing, scheduling, and load balancing
Flexible routing, scheduling, and load balancing
30–40% capex reduction
Automating defect detection
Automating defect detection
90% improvement in defect detection
Extension of automation to final and pre-assembly
Extension of automation to final and pre-assembly
<20 months amortization
Paperless work instructions
Paperless work instructions
+10% production yield
Closed quality loops through sensor-based in-line quality inspection
Closed quality loops through sensor-based in-line quality inspection
<1 sec inspection time
Conquering remaining domains of manual labor through automation
Conquering remaining domains of manual labor through automation
80% labor cost reduction
DMG Mori technology helps Martin-Baker achieve 80% OEE in high-variant machining
Case example 3 / 9
Based on an in-depth analysis of the manufacturing process and OEE drivers, DMG Mori supported Martin-Baker in reaching 80 percent OEE in a 24/7 manufacturing operating model with one manned shift and two unmanned shifts. Traditional pallet-based machine loading automation solutions and an integrated software solution reliably a) monitor and detect tool wear, tools blockage, and missing material and b) automatically adjust job sequences and send failure notices to the central production monitoring control room. Together, these solutions helped bring OEE to 80 percent in critical machining areas.
80%
OEE
Up to
Porsche deploys a flexible AGV-based assembly line to optimize its electric vehicle production
Case example 4 / 9
Porsche is introducing an AGV-based assembly process for the serial production of its electric model, Taycan. Instead of merely using AGVs to transport vehicles between assembly stations, the flexible production line concept uses a takt sequence with assembly workers moving with the AGV through the manual assembly processes, following a flow principle. At the same time, the AGV concept allows vehicles to leave the main line flow when necessary, e.g., for the installation of special interior features, thus allowing balancing.
The AGV-based production line should require 30 to 40 percent less capex than the traditional main line, with most savings coming from reduced weight and related building cost reductions. In addition, the concept promises higher efficiency in operations and shorter ramp-up times from pre-series to series production, as pre-series production concepts can be moved into the series production factory.
30–40%
Less capex
Ford automates quality control through camera-based in-line quality inspection
Case example 5 / 9
Ford Motor Company uses JAI machine vision cameras for in-line quality control of the painting process to improve defect detection. Ford installed JAI’s automated vision systems to identify dirt particles in paint jobs as a replacement for manual car inspections, which only identified about 50 percent of defects.
JAI’s machine vision system consists of 16 high-resolution cameras, detecting dirt particles that are smaller than a grain of salt. The cameras take more than 1,000 images of each painted vehicle surface to create a 3D model of the car bodies in order to identify defects. After introducing this completely automated vision-based inspection system, Ford saw a decrease in inspection times due to the system’s high viewing rate of 15 frames per second, and a 90 percent improvement in defect detection compared with human inspections.
90%
improvement in defect detection
Bosch increases end-of-line parts inspection efficiency via flexible and collaborative robotization by Rexroth
Case example 6 / 9
Bosch uses collaborative APAS robots for automated end-of-line inspections on the manufacturing line for automotive fuel injection system components. By combining a collaborative APAS robotic arm with a sensor-based quality inspection module, Rexroth created an efficient end-of-line inspection workstation that achieves an OEE of over 90 percent. The solution is also highly space efficient and flexible due to its fenceless setup. In addition, the cell allows for short interruptions of the workflow by automatically and safely stopping the robots via a capacitive sensor skin when workers enter the cell area.
This flexible automation solution was amortized in less than 20 months and represents a significant cost savings over the previous manual inspection setup.
<20 month
amortization
Samsung uses cutting-edge 3D vision scanning to tackle growing demand and strict quality standards for LCD panels
Case example 8 / 9
Samsung introduced 3D scan-based automated inspection to replace the manual process of inspecting LCD panel flatness, which proved to be a bottleneck in the manufacturing process. Automated in-line inspection is based on color filter inspection systems operating at the same speed as the production line. The system identifies internal panel and surface defects. It reports defects in real time to operators, with the precise X-Y coordinates of the issue and information on the type of defect. Changing to sensor-based in-line inspection increased the speed of the inspection process from minutes to less than one second per screen. Production line output and throughput times improved significantly, eliminating this bottleneck in the inspection process. Customers benefited from defect-free products as a result of upstream defect identification and resolution.
<1 second
inspection time per screen
Global electronics contract manufacturer introduces robotic automation solutions to reduce its labor cost by 80% in selected areas
Case example 7 / 9
A global electronics contract manufacturing company started its enterprise-wide digital manufacturing transformation journey with a detailed evaluation of its manual operations. It identified robotics technologies that made it possible to automate manual tasks. These were predominantly found in pick and place, screwing, labeling, and some wiring areas, as well as in connector plugin applications. The company also identified the automation of quality assurance processes as a high potential application. It designed a lead automated line by rethinking processes and developing solutions that enable a high level of flexibility to accommodate multiple future products. As a result of the higher degree of automation, the company reduced its labor costs by 80 percent and reached significantly higher levels of process efficiency and quality.
80%
labor cost reduction
Jabil Circuit gains 10% production yield through interactive work instructions
Case example 9 / 9
Jabil Circuit uses tablet-based interactive work instructions from Tulip to guide electronics assembly and run process analytics at the same time. Customized apps provide the operators with visual instructions about the assembly steps, enabling them to track and report quality issues in real time. The system has fully replaced former paper-based work instructions and audit procedures, and the data gathered from the shop floor are continuously analyzed by Tulip’s analytics engine. Within four weeks of implementing the digital work instructions, Jabil Circuit gained a more than 10 percent increase in production yield and a 60 percent reduction of manual-assembly-related quality issues.
+10%
production yield