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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.
We developed Shannon® and Darwin to solve those challenges in the Automotive context:
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
"The cycle time analysis of Shannon® visualized and compared the cycle and process times for the relevant intervals at detailed station level. This enabled us to initiate concrete optimizations for individual stations to reduce the overall cycle time."
Andreas Koellner
PLC Technician, Production Process Engineering, ebm-papst St. Georgen GmbH & Co. KG
Automated assembly line for mechatronic components including 14 stations and 15 PLCs. Already high production rate of 92 % and cycle time of 8s. Operational shopfloor assistance Shannon® for continuous productivity optimization.
Solution: DataCollector for high-frequency data collection of all legal machine controllers & Shannon®, the operational Shopfloor Assistance
"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
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.
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: DataCollector for high frequency data collection of all legal machine controllers & Shannon®, the operational Shopfloor Assistance
Darwin, the Machine Performance Finder, offers several intelligent functions to identify concrete optimization potentials of an automated production line during operation. In this way, it significantly increases the performance level of the machines.
