The auto sector has historically been challenged to constantly cut costs and drive efficiencies, and these pressures are expected to intensify over the coming decade. In response, many automotive suppliers are enhancing their continuous improvement efforts to make them more impactful and position themselves ahead of the competition.

10in6 currently works with manufacturers in Tier 1, Tier 2 and Tier 3 of the automotive supply chain. From forging and stamping cells, to complex assembly lines, 10in6 has the flexibility to be configured to your specific processes, helping you improve efficiency, quality, and overall plant operations.

For example, we recently helped a Tier 1 Automotive Supplier of fluid power solutions achieve significant improvements to First Time Quality (or FTT) and OEE in under 6 months with the 10in6 Scheduled Checks module. By replacing time-consuming paper quality checks with automated paperless tracking, the supplier has more time to focus their improvement efforts on the issues that matter most. Read the full case study.

SOLUTIONS:

• Driving Operator performance accountability with configurable Real-Time Andon display boards
• Cutting warranty and scrap costs using Traceability
• Eliminating constraints in high volume repetitive manufacturing processes using Constraint Management
• Re-focus continuous improvement efforts with Production Reporting that prioritizes where to implement improvements, and ensures that those improvements are sustained.
• Reducing wasted time during product changeovers by implementing management solutions that drive accountability to changeover times and procedures. 
• Providing real time scheduling integration to ensure customer orders are optimized based on the realities of the shop floor – including visibility of Real-Time order progress, and Alerting for orders that are projected to be late.  
• Reducing time operators spend waiting for quality, maintenance, materials and other line support staff with Andon Call Buttons.  Automatically tracking response times and the reasons for calls provides valuable insight on disruptions to your standard operating procedures.

Each of these solutions has resulted in quantifiable and measurable efficiency gains for our automotive clients, resulting in an overall lower cost/unit in the manufacturing process. Contact us today and we will help you build a business case based on a short-term payback model that generates results quickly.

The challenge in high speed packaging lines is to keep product flowing without disruption.  When these lines are operating well, you’re making money.  When one piece of equipment is down, the entire line is down and your profits are quickly being eroded.

10in6 helped a Butter and Cheese Manufacturing Cooperative client improve their OEE from 43% to 60% in three months using a custom-built system of several 10in6 modules. By implementing custom Efficiency, Quality, and Operations tools, the client and their team were finally getting the information they needed when they needed it, in order to make faster and better-informed production decisions on the shop floor. Read the full case study here.

SOLUTIONS:

• Analytics and production reporting to highlight losses in efficiency and break them down into simple, actionable categories, such as:
  • Change-over losses
  • Startup losses (product changeover times – losses during the critical startup phase after a product change)
  • Speed losses (under speed)
  • Downtime Losses – equipment failure, plant breakdowns, production stoppages
  • Uptime Losses – material shortages, operator issues, etc.
  • Giveaway
• Improving changeover performance by utilizing changeover management techniques that drive true accountability to all phases of the changeover:
  • Tear-down phase & cleanup
  • Changeover phase (equipment, product and materials changeover)
  • Startup/ramp-up phase
• Schedule Execution to ensure customer orders are optimized based on the realities of the shop floor. This includes viewing Real-Time order progress, and Alerting with updates for orders that are projected to be late.
• Constraint Management to identify specific pieces of equipment that chronically underperform to line rate.
• Scheduled Checks that reduce losses due to incorrect packaging or materials, missed date codes, and more – ensuring all checks are done on-time, using the most recent work instructions.

The consumer packaged goods sector of manufacturing has been faced with two extreme challenges:

1) An increasing rate of new product launches to lure today’s savvy consumer

2) Global downward price pressure as a result of the economy

In other words, the classic battle – do more & do it with less money.

10in6 has assisted manufacturers in the consumer package goods arena to re-focus their continuous improvement programs in order to help win the battle.

SOLUTIONS:

• Drive accountability to existing continuous improvement programs through simple and configurable production reporting systems that do not rely on tedious manual data entry.  These systems quickly become the “record of truth” and ensure the right projects are selected and that improvements are sustained over the long run.
• Drive accountability to shop floor performance by utilizing Real-Time Andon display boards to set targets and goals on an hourly/shift basis with the opportunity to react to issues as they happen.
• Implement Constraint Management techniques to ensure the constraining operation (by product) is understood and improved so overall flow is improved and end-of-line results are realized.
• Improving changeover performance by utilizing changeover management techniques that drive true accountability to all phases of the changeover:
  • Tear-down phase & cleanup
  • Changeover phase (packaging equipment, product and materials changeover)
  • Startup/ramp-up phase
• Provide real time scheduling integration to ensure customer orders are optimized based on the realities of the shop floor.  Our scheduling integration features include being able to see Real-Time order progress, and Alerting for orders that are projected to be late.
• Reduce losses due to packaging errors (wrong accessories, labels, or feature options.) Digitize your equipment start-up, change-over and in-process quality checks with our Scheduled Checks module.  Ensure all checks are done on-time with the most recent work instructions for plant floor set-up and changeover. 
• Limit recall scope and customer complaints with our traceability (lot or serialized unit) and error-proofing solutions.

Operating a manufacturing environment that generates hundreds or thousands of products in low quantities at profitable levels represents the biggest challenge in manufacturing custom-made and low volume products. The world-class leaders in these markets are those that have mastered the ability to reduce manufacturing lead times by improving manufacturing flow and throughput. This results in shorter delivery times, increased revenue and reduced manufacturing costs

SOLUTIONS:

• Providing real time scheduling integration to ensure customer orders are optimized based on the realities of the shop floor.  This includes alerting and messaging in the event of orders that are projected to be late.
• Providing accurate operator performance tracking to ensure fairness in employee performance reviews.
• Improving changeover performance by utilizing changeover management techniques that drive true accountability to all phases of the changeover.
  • Tear-down phase
  • Changeover phase (equipment, product and materials changeover)
  • Startup/ramp-up phase
• Deploying Real-Time Andon display boards to provide visual operator feedback on performance and schedule attainment.
• Reducing losses that were previously caused by incorrect settings, procedures or out of specification products. Automate your start-up, change-over and in-process quality checks with the Scheduled Checks module.