Optimizing Factory Performance

A discrete parts manufacturer in the automotive industry faced difficulties in managing a multi-step production system with parallel machining, assembly, and final assembly flows. Variations in shift schedules and process constraints made it challenging to maintain a smooth and efficient operation across the entire factory.

Challenge

A production facility struggled with high buffer levels, long lead times, and inefficiencies in product sequencing. These issues led to:

• Increased production costs due to excessive material storage.
• Delays in production flow impacting delivery timelines.
• Difficulty in balancing shift work and workforce allocation.

Solution

With FACTS Analyzer*, the company could:

• Reduce buffer and store levels while ensuring uninterrupted production.
• Analyze and optimize product sequences to minimize wait times.
• Evaluate different shift configurations for increased efficiency.

Results

• 25% reduction in buffer/store levels.
• Shorter lead times, improving overall factory performance.
• Optimized shift patterns leading to improved workforce utilization.

Conclusion

With data-driven insights and simulation-based optimizations, the company achieved higher productivity, reduced operational costs, and improved production flow.

*FACTS Analyzer was the previous generation of inFACTS Studio, built on a 2D environment.