How Touchscreens Can Motivate Assembly Line Workers to Do Quality Work
When UTC Aerospace required a solution to manage assembly line workers with no previous manufacturing experience, it decided to try something new that set a precedent for its future manufacturing operations management (MOM) strategy.
PINpoint Information Systems Inc.Lean manufacturing is about eliminating waste, reducing cost, improving efficiency, and quality: PINpoint Information Systems takes you there. Working alongside and pushed-forward by leading manufacturers, we've been championing "Continuous Improvement" since 1997. We are a leading manufacturing execution system (MES) / manufacturing operations management (MOM) software developer.
UTC Aerospace / Boeing 787
- CONNECTIVITY PROTOCOLS
Using manufacturing software from PINpoint Information Systems that features situational awareness graphics on plant floor touchscreens, the manufacturer was able to train an unskilled workforce to build safety critical electronics without defects, which actually helped ramp up production within days, said UTC Aerospace. With the software monitoring and controlling the hundreds of process steps needed to build the products, problems and defects could not go unchecked so error-proofing was maximized.
- DATA COLLECTED
Process Parameters, Process Procedure, Instructions
- SOLUTION TYPE
- SOLUTION MATURITY
Mature (technology has been on the market for > 5 years)
- OPERATIONAL IMPACT
Impact #1 [Efficiency Improvement - Integration]
Quick integration of software on the plant network, followed by a rapid ramp up of production all within 5 days. Assembly line work station operators and line area supervisors are guided by the Manufacturing Execution System (MES) to perform process steps, such as fastening operations, correctly within the MES software's configured parameters; and on time (within cycle time / Takt).
Impact #2 [Efficiency Improvement - Quality Assurance]
Assembly line error-proofing is maximized since the MES provides invaluable Manufacturing Intelligence (MI) in the form of manufacturing reports created from all historical data, or in real-time via the Performance Dashboard website that reports OEE on-the-fly and is accessible from any computer or wireless device from the cloud.
- QUANTITATIVE BENEFIT
Rapid MES intigration with production starting and ramping up quickly within 5 days. Assembly line workers who had no previous experience in the assembly of electronic motor controllers (safety critical parts) for the Boeing 787 dreamliner were guided to do so within days, with no defects, and within Takt time.
"PINpoint taught us what accountability of process really means, the financial value of that and how to maximize the benefit of the assembly equipment we already owned."
- UTC Aerospace Systems
Maximized product quality, and increased assembly line efficiency overall. Short return on investment (ROI) payback time within 1 year.
- USE CASES
Factory Operations Visibility & IntelligenceVisualizing factory operations data is a challenge for many manufacturers today. One of the IIoT initiatives some manufacturers are pursuing today is providing real-time visibility in factory operations and the health of machines. The goal is to improve manufacturing efficiency. The challenge is in combining and correlating diverse data sources that greatly vary in nature, origin, and life cycle. Factory Operations Visibility and Intelligence (FOVI) is designed to collect sensor data generated on the factory floor, production-equipment logs, production plans and statistics, operator information, and to integrate all this and other related information in the cloud. In this way, it can be used to bring visibility to production facilities, analyze and predict outcomes, and support better decisions for improvements.