Bodyshop Ramp-Up and Redesign

Context

Bringing a Body in White Factory at Its Full Potential After the Introduction of a New Car

A new platform is introduced in an existing factory to produce a new car model. The factory has an excellent yield before the introduction of the new platform. The implementation of changes leads to a drastic loss of factory efficiency. Thanks to a vigorous campaign of kaizen, the factory regains a sizable portion of efficiency yet remains far from its OPR (Operation Production Ratio) target.The client contacted us with the following request:

• Can the current factory structure achieve our efficiency OPR target? 

• If not, what are the changes needed to this end?

Our Solutions

Use of DispoX by Our ExpertsWe built a specific interface that absorbs production reports automatically. DispoX then injects them into the factory’s digital twin to estimate the isolated performance of each module and the overall efficiency of the whole factory. We added optimization algorithms that help identify optimal changes to be implemented (MTTRs, MTTFs, cycle times, buffers' size, ….) and ranked them by benefits on a waterfall graph

Benefits

OPR Reached the Target, and the Time to Solution Drastically Shortened. Dillygence experts use their expertise and their tools to identify a set of actions to be implemented:

• The decision was made right after a presentation to the senior management, thereby drastically shortening the decision time

• Thanks to the Dillygence tools, our experts could zero in on the just-needed actions, limiting our client's investments

• The client team implemented the changes to reach their OPR target