White Papers
Aerospace Component Manufacturer
Production Monitoring System
Aerospace Components Manufacturing
Customer Issues
- Need to Capture Accurate Assembly Times for Each Manual Assembly Step on a Production Line
- Visibility on the Production Status of Each Individual Work Order Through Each Production Step
- Notification When a Work Order is Behind Schedule
- Need to Reduce Response Time to Issues on the Production Floor by Support Personnel
- Overview Visibility for the Status of the Production Floor
Production Environment
The production environment is a very complex manufacturing environment with a large spread out production floor. Each work order flows through multiple production lines to produce a final product. Each production line consists of both manual assembly operations and machine production steps. Production lines also include a quality review function as one of the steps. Due to the complexity of the production process with work orders moving through multiple production lines, it is very difficult for management to achieve an accurate understanding of the status of work orders at any one time. Visibility on both the location of the work order on the production floor and time for completion of a work order is critical to production management to maintain management control over the production floor.
VersaCall Solution
VersaCall System solution provides complete production status visibility of the entire production process. Wireless input modules are strategically located throughout the operation at each production step including the quality step. The VersaCall input modules capture all production performance information, location, machine and assembly time, operator efficiency, downtime occurrences by reason code and safety incidents. The System supports the immediate communication of issues, as well as supporting instant line stoppages for quality or other production issues.
Visual Status – Total Production Floor By Line
One Screen provides the entire status of the production floor.
This visibility includes which work order is at which step.
It also indicates if the work order has an issue by color designations.
Drill Down Provides Step Production Visibility
Click on the main screen and you now see the detailed status of the production step.
Information includes both work order completion status, and the percentage of completion.
Drill Down Screen Also Provides Location On/Behind Schedule Visibility
The Drill Down screen from the main plant screen also provides where the work order is and whether it is on schedule for the planned production time or if it is behind schedule
Automatic immediate communications are sent out when the work order is behind schedule or
Immediate Communication Of Issues
Production floor issues are immediately communicated to the appropriate individuals. Response time is captured for each incident. This includes work orders with issues. All this information, including root causes, are automatically recorded in a database for reporting
All production disruptions are minimized with the VersaCall System.
Analytics
Results After System Implementation
- 5% Increase in production output.
- One screen – complete production status visibiliy
- Accurate capture of production labor time for both manual assembly and machine operation
- Immediate communications of all production issues including work orders behind schedule
- Visual detailed status of every production work order
- Location ▪ Percent complete ▪ Labor hours incurred ▪ Completion time
