Discrete Manufacturing

In discrete manufacturing production is usually controlled by work orders being issued to the shop floor.  Discrete manufacturing will often be controlled and planned by operations and routes with the final part being produced by several or many machines and processes. The synchronization of production within the factory is critical for maintaining flow and removing bottlenecks.

 
Units can be manufactured in low volumes with high complexity or high volumes with low complexity. Where low volumes are made the equipment needs to be extremely flexible. High volume production puts high pressure on machine utilization and efficiency, material usage and costs.

 
Gemba’s Modular GAIN4 solution addresses discrete production problems with the following features :

 

  • User Configurable real-time production scoreboards (GAIN4 Andon)
  • Kanban systems for delivery of materials to lines (GAIN4 Andon)
  • Performance improvements through OEE initiatives (GAIN4 Efficiency)
  • Real time monitoring of downtimes and the reasons for them (GAIN4 Efficiency)
  • Planning production against operations and routes (GAIN4 Planning)
  • Monitoring and predicting change over’s and setups (GAIN4 Alert)
  • Tracking production progress and inventory levels (GAIN4 Tracking)
  • Recording of in process quality checks (GAIN4 Quality)
  • Analysis of production bottlenecks (GAIN4 Advanced reporting)

 
Benefits:

 

  • Delivers production plans directly to the shop flow by integrating to the companies ERP system
  • Ensures realistic production plans by using historical efficiency figures and change over times while planning
  • Identify machine downtimes and performance rates enabling improvements in capacity and efficiencies
  • Monitoring quality processes within the manufacturing process allows reject rates to be minimized
  • Provide shop floor production incentives via visual management systems
  • Drive improvements in supporting processes such a material delivery to the machines avoiding delays due to shortages
  • Remove time lost to waiting for subcomponent manufacture due to planning and tracking failures

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