Accurate control of manufacturing oprations

The Internet of Things (IoT) provides all required data to plant managers offering full view and control of automated manufacturing operations in real-time. This capability allows manufacturing leaders to manage global material supplies, logistics execution and production operations for one site and then execute across all sites.

Visibility into operations (both within a single plant and across all plants) results in better alignment with business performance targets. Using Build Control, part of Build to Operate, means manufacturing leaders have a paperless, fully traceable means to manage production, offering more structure and insight than simple ERP data alone.

Key capabilities & benefits : 

• Accelerates program profitability through deployment of a global lean manufacturing system
• Increases program operational control and flexibility via real-time global visibility and control of manufacturing operations for one site or global sites
• Enforces procedural control during build phase by aligning people, processes, equipment and products

Optimize your supply chain

With shorter product life cycles, a focus on first time quality and profits, aerospace manufacturers are focused on lean supply strategies. Manufacturing VPs and plant management can now monitor, control and optimize the flow of deliverables across the supply chain into manufacturing operations.

They also have the capability to better manage the implementation of new technologies like additive manufacturing because of the ability to integrate suppliers into manufacturing operations and planning.

Key capabilities & benefits : 

• Minimizes risk of incomplete supply chain deliveries by providing full visibility of status and content of your suppliers
• Increased manufacturing operations flexibility allows faster recovery in the stance of a late or missed supplier delivery
• Better integration of your supply chain into your manufacturing operations improves lean manufacturing by removing or minimizing wasted time, materials or defects

First time build quality accelerates rate

With the Build to Operate solution, companies can reach full manufacturing rate faster through replicable processes, optimized production sequences and the ability to achieve first time quality across all sites. Quality engineers have the data to quickly identify root causes of production errors and failures and adjust processes and make corrections in real-time.  Manufacturing engineers have the ability to implement best practices by using natural language rules for clear real-time recommendations to shop floor workers during execution. The impact is increased production volume and reduced scrap and rework.

With Build to Rate, manufacturers leverage full Manufacturing Operations Management (MOM) capabilities to monitor, control and validate all aspects of manufacturing with digital precision.

Key capabilities & benefits:

• The ability to introduce new technologies more simply results in increased efficiency of existing (enhancing) or new (green field) production lines
• Delivering the right work instructions at the right time decreases installation and asssembly cycle time
• Unified engineering and manufacturing change management increases efficiency of non-conformance resolution
• Real-time traceability of supplier as-built data enabling quick containment and disposition of quality issues minimizes the risk of installing defective components

Lean improvements for first time quality

Continuous Build Improvement provides Plant Managers with improved visibility and 24/7 Operations Control to improve manufacturing processes.

Supporting continuous improvement, also known by the Japanese term Kaizen, plant managers and manufacturing engineers have the ability to eliminate waste through advanced analyses of all relevant manufacturing data. The analysis uses On-line Analytical Processing (OLAP) cubes that includes manufacturing KPIs, metrics and other data. Having immediate access to this manufacturing big data promotes first time quality though preventive actions, continuous production optimization and by avoiding non-conformance issues.

Part of the Build to Operate Industry Solution Experience, Continuous Build Improvement allows manufacuters to pursue first time quality with lean improvements such as:

• Up to 25% lower manufacturing defects
• Up to 75% reduction in defect analysis cycle time
• Up to 20% increase manufacturing capacity

• Detect and lower or avoid quality risks in real-time by monitoring shop floor data and proactively preventing scrap and rework
• Identify root causes and prevent composite or additive manufacturing defects also through analyses of shop floor data to uncover previously unexplained voids and delamination defects
• Implement lean practices such as continues improvements via Internet of Things (IOTs); smart devices which collect job relevant data used in certification and shop floor analytics
• Validate, control and improve line automation performance through analytics of line performance, warning and failure information accomplished via a simulated “replay” environment – all features of today’s future factory.