Creation and implementation of a Dynamic Balancing solution (task sequence monitoring) to improve factory efficiency.

ALSTOM and APPRODUCTIVITY 4.0 - We refine the software and respond to ALSTOM's needs.

Integration of a new APPRODUCTIVITY 4.0 module: Dynamic Balancing (EQUDIN-MES).

Case Study

ALSTOM needs to monitor the progress of the train manufacturing process in order to know, from the beginning and in real time, the possible deviations from the Process Engineering forecasts (Static Balancing) in order to be able to take appropriate corrective action before these possible deviations become a problem for the achievement of the planned production goals.

To this end, we developed a Dynamic Balancing solution (task sequence monitoring), to be integrated as a new module of ItemsaSoft PROCESOS® -currently APPRODUCTIVITY 4.0-, called MES-EQUDIN.

Initial situation

The Factory did not have a system to control the progress of the work.
Until the end of each work shift, it was not known which tasks had been completed, which were in progress and which had not been able to start.
This lack of information due to the lack of a Task sequence tracker did not allow timely corrective action.
There was no MES (Manufacturing Execution System) which would allow the status of the work progress to be known at any point in time, so that if necessary, the tasks and resources could be re-planned in order to comply with the production plan.

Goals

Improve Factory efficiency (OEE).
Develop a Dynamic Balancing solution (Task Sequence Monitoring System) which would allow to:
- Know the status of each operation in real time:
  - In process “on time”.
  - In process “delayed”.
  - Delayed.
  - Interrupted (lack of material, no operator, …).
  - At risk of a delay.
  - Etc.
- Reprogramming in real time:
  - Add or remove operators.
  - Change the task sequence.
  - Move operations to a "bubble" of pending operations.
  - Extend or reduce work shifts.
- Transfer information/documentation to the shop floor within a paperless system:
  - Standard Operation Instructions (SOI).
  - Quality / Internal control.
  - Special processes.
  - Safety Operations.

Results

Through the implementation of APPRODUCTIVITY 4.0 and the development and integration of the new Dynamic Balancing module (MES-EQUDIN) we achieved:

A significant improvement in the efficiency of the factory thanks to:
- Knowing the progress status of the tasks at all times.
- Being able to detect deviations in real time.
- Being able to immediately take corrective action by reprogramming work shifts, the number of operators, task sequences, etc. in real time.
All processes and the documentation associated with them (SOIs, lists of materials, tools and other means, procedures of internal control, AMFES, etc.) will be digitalized and all documentation on paper eliminated in the workshop.
Management is unified and simplified thanks to the guarantee that only the very latest version of the documentation is available: Standard Operation Instruction Worksheets (SOIs), BOMs, tools and tooling, etc.
The program provides a tool that allows an immediate rescheduling of the tasks in the event of any setback (delay, lack of material, absence of operators…).
The training and certification of operators for special operations is guaranteed.
The new software, and therefore the implemented solutions, are integrated into ALSTON's ERP, which results in positive synergies, allowing the unification of information and improvement of efficiency.