OEMs: Cars, Trucks, Motorcycles & All Assembled Products

OVERVIEW

Product manufacturers, such as Auto OEMs, have derived significant benefits by deploying Optessa’s products for:

The assembly line sequencing and scheduling problem is large and complex, as can be seen in the image below relating to the Auto industry. Optessa MLS can generate near optimal solution to these complex problems.

Interdependencies between plant, customer orders & dealers, and suppliers for the auto industry resulting in complex assembly line sequencing requirements

Strategic benefits
  • Improved throughput
  • Align demand and delivery
  • Reduce order to delivery lead time
  • Reduce finished goods inventories at dealers and system
  • Fulfill each order: improve market share
  • Improved flexibility and reduced response times, allowing late commitments
Operational benefits
  • Evenly favorable solution that considers all rules and constraints
  • Reduced costs: e.g. paint purges
  • Improved FIFO conformance: reduced buffers of painted bodies
  • Constraint violations are smoothed and not bunched
  • Reduced parts and in-process inventories
  • Better synchronization with suppliers and feeder lines
  • Options / features smoothing and leveling (“Heijunka”)
  • Re-sequencing with a bias to stability
  • Improved accuracy and reduced sequencing process times

Optessa MLP or a combination of Optessa MLP and Optessa MLS can be applied to a variety of planning problems in the auto industry.

Regional planning

Multi-plant planning at a regional level considers inputs from:

  • Demand forecasts
  • Marketing rules and constraints – regional / dealer allocations and rules
  • Production capacities – in-house and suppliers
  • Material, plant and labor constraints
Scheduling of forecast and actual / fixed orders
  • Order slotting / assignment to plant and build monthly / build weekly / build day
  • Regional and dealer constraints and allocations
  • Supplier / in-house capacities
  • Plant and labor constraints
Order substitution
  • Matching and substitution of forecast with actual orders
Critical constraint checking and optimization
  • Long lead time and capacity constrained parts: in-house and suppliers
Forecast order generation
  • Valid order configuration templates
  • Feature or equipment mix forecasts
  • Important material, plant and labor constraints
  • Important marketing rules and constraints
Benefits of Planning with Optessa MLP
  • Optimize against all supplier, in-house, plant and labor constraints
  • Stability for material planning
  • Multi-plant and multi-line balancing
  • Combined planning and sequencing
  • Increased flexibility and reduced response times
  • Increase number of total orders selected
  • Increase % of actual orders selected
  • Better matching during order substitution

Optessa MLS can be applied for sequencing and re-sequencing / rescheduling of an entire assembly plant or sections of an assembly plant. The operating mode can be in-line and automated or on-demand.

IN-PLANT DETAILED SEQUENCING & SCHEDULING – EXAMPLE, IN-LINE VEHICLE SEQUENCING (ILVS)

Below are examples of Optessa MLS in-line sequencing applications with reference to car plants but other manufacturing environments would benefit from in-line sequencing and scheduling.

  • Plant consists of different areas (Weld/Body, Paint, Trim, Final Assembly) – each area may have one or more lines.
  • WIP storage buffers, such as ASRS or Lane Banks
  • Sequencing rules and constraints derived from the plant, suppliers and orders (demand) related
  • Large order sets: daily sequence may have 1,000 orders, weekly sequence between 5,000 – 1,0000 orders and monthly sequence over 10,000 orders

Given a single set of orders, Optessa MLS can generate:

  • A single “virtual” sequence for multi-line plants or a distinct sequence for each line in the form of series of synchronized sequences, and
  • A single sequence from Weld-On to Assembly-Off or different sequence for each area

Please see below for a representative image of the plant sequencing problem. (Note: the image is intended to be representative; plants may consist of more or fewer lines.)

 

Representative image of the plant assembly line sequencing problem

Optessa MLS has solved this problem – it creates the best sequence possible for the given data, requiring no additional manual adjustments. Optessa MLS can be integrated with both MES and ERP systems for seamless and automated sequence generation and committing.