Case Studies - Automotive
Solution : Evaluating new
equipment and processes
We provided the modeling, manufacturing process analysis and recommendations
needed for GM to make a critical launch decision that saved millions
of dollars. GM and a tier-one supplier were uncertain whether a
new manufacturing process design for a critical stage of the new
vehicle would produce the desired jobs per hour. Our predictive
technology modeled the new process and found that it would NOT by
30% because of an unexpected constraint. Our recommendations were
implemented and the launch was saved. The supplier retained the
PROMODEL custom software solution in order to make additional process
improvements.
Solution : Capacity analysis and improvement.
Paint lines are often a source of intense study and desired improvement
- from auto companies, to motorcycle manufacturers and to Carrier
Corporation, part of United Technologies. The PROMODEL predictive
analysis software was used to accurately model their refrigeration
equipment paint line and make some startling and valuable discoveries.
Among the discoveries was finding that over $800K of throughput
improvement projects planned for the plant would have little or
NO impact on throughput. Instead, installing a new paint oven WOULD
help and have an annual benefit of $370K. The decisions powered
by PROMODEL technology resulted in savings to Carrier of over US$1
million.
Solution: Reducing inventory
Complex and highly variable manufacturing processes can't be accurately
modeled with traditional spreadsheet techniques. Fiat found that
a predictive technology solution powered by PROMODEL enabled them
to accurately model their process and then reduce work-in-process
inventory by 48%, reduce lead times and reduce space requirements.
From the dozens of possible improvement initiatives, the software
solution enabled them to identify specific plant scheduling changes
and process improvements that resulted in a large return on investment
and over US$1 million savings.
Solution: Transportation system design
Volkswagen relied on PROMODEL predictive technology to make major
changes in their highly variable and complex vehicle distribution
network. Savings were over US$20 million per year. A custom solution
for their plant-to-distribution center-to-dealer delivery system
was built using PROMODEL technology. Multiple improvements were
identified and implemented. These included changing distribution
center locations and subsequently replacing some expensive truck
routings with cheaper rail or sea routes. Benefits to Volkswagen
included both lower costs and improved customer service.
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