plus10 Success Stories

Automotive

Cost-efficient operations of complex manufacturing lines

The automotive industry faces huge challenges in the production context. The high complexity and the high level of automation need to be handled without suffering from unplanned downtimes such as short stops, technical disturbances or machine breakdowns as well as subsequent troubleshooting.

Operational excellence is required at every factory to remain competitive which means, knowledge about machine behaviour and technology needs to be available and provided to every operator in every plant around the clock whenever needed.

Lastly, the current technology change leads to higher requirements in cost efficiency, flexibility and productivity.

We developed Shannon® and Darwin to solve those challenges in the Automotive context:

Shannon® for Automotive

Shannon®, the Real-time Solution Recommender, provides situational problem-solving proposals for employees responsible for automotive production lines to reduce downtimes during breakdowns and short stops. The tool thus forms a continuously effective optimization loop based on high-frequency machine controller data. Shannon® makes expert knowledge about problems and their solutions explicitly available to the entire staff worldwide at the right moment in a mobile app.

Benefits of Shannon® for Automotive

  • 5-15% increase of production effectiveness (OEE) due to reducing downtimes and troubleshooting (MTTR)
  • Increasing cost efficiency by reducing unit costs
  • 10-30% shortening the ramp-up and relocation phase in the global production network
  • Instant problem solving support by suggesting most-relevant expert knowledge

Success Story: Shannon® at Freudenberg Filtration Technologies

Data-driven explanation of short-stops, breakdowns and related scrap of a production line for car cabin air filters

Scope

Fully automated production line for car cabin air filters consisting of 21 processes with initial efficiency rate of 79% – 92% depending on individual product type and shift.

Target

Detection  and quantification of optimization potential regarding short stops, breakdowns and related scrap. Based on that generation of situational counter-actions to reduce troubleshooting efforts.

Solution

for high frequency data collection of all legacy machine controllers

the real-time solution recommender

Benefits
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© plus10 GmbH
  • Full transparency regarding root-causes of short-stops, breakdowns and scrap summing up to 9% of unplanned downtime and 3-13% of scrap
  • 80 situational counter-actions generated during initial test phase which are actively used for operational trouble-shooting
  • 22 quantified and prioritized technical optimization actions generated for mid-term optimization and maintenance actions
  • Trend analysis for mean-time-to-repair and mean-time-between-failure for each individual root cause and correlated counter action to measure effectiveness of defined actions over time

"After a short training phase of Shannon® it was applied to one of our fully automated productions lines. The real-time transparency on error behaviour, associated scrap per cause and situational problem-solving proposals during operations helps us a lot to limit losses to a minimum around the clock!"

Ed Borger

Vice President Global Operations, Freudenberg Filtration Technologies SE & Co. KG

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Darwin for Automotive

Darwin, the intelligent machine benchmark, learns a virtual ideal process on the basis of high-frequency PLC data from several machines and thus provides a target value how fast each machine could be and how to get there. Darwin continuously generates specific recommendations for reducing the cycle time for each machine. Thanks to early warnings, maintenance departments are empowered by Darwin to avoid breakdowns before they happen.

Darwin as intelligent machine benchmark focuses on cyclic automotive production processes, e.g. injection moulding, deep drawing, extrusion or metal stamping.

Benefits of Darwin for Automotive

  • Increase of output rate per machine by reducing cycle time
  • Reduction of throughput times
  • Explanation why similar machines perform differently at the same or different factory
  • Early warning system before breakdowns happen

Optimize your automotive production with plus10!

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