Revolutionizing Production Line Changeovers for a Leading Automotive Manufacturer

A global automotive technology leader partnered with Aspecta to address inefficiencies in production line changeovers at its Slovakia facility. By implementing Solvedio's cloud-based Changeover Tool, the company achieved a 30% reduction in changeover times, improved coordination by 40%, and increased production flexibility by 20%, enabling faster market adaptations while maintaining top-tier product quality.

By Team SOLVEDIO │ Updated November 26, 2024


 

Client

A Global Automotive Technology Leader

Executive summary

A leading automotive technology company faced inefficiencies in managing production line changeovers at its Slovakia facility, resulting in extended downtimes and coordination challenges. Aspecta partnered with the company to implement a cloud-based Changeover Tool powered by Solvedio, providing real-time tracking, role-based task management, and resource optimization. The solution significantly reduced changeover times, enhanced coordination, and increased production flexibility. This transformation allowed the company to uphold high product quality and swiftly adapt to changing market demands, with the project completed across a series of key milestones.

About

The client is a subsidiary of one of the world’s most esteemed automotive technology companies, with a heritage dating back to 1871. Originating as a tire manufacturer in Germany, the company has evolved into a global leader in automotive innovation, employing over 240,000 people worldwide. Their diverse portfolio includes tires, braking systems, automotive electronics, and more, with a strong focus on autonomous driving, green transport, and safety solutions.

 

What They Say

"The Changeover Tool has revolutionized our production process. We've seen remarkable improvements in efficiency, coordination, and overall flexibility, enabling us to meet market demands more effectively than ever before."

— Production Manager
 
 

 

The Problem

The production facility in Slovakia, a critical hub in the company’s global manufacturing network, faced significant challenges in managing production line changeovers. Inefficient processes resulted in prolonged downtimes, inconsistent changeover durations, and difficulties coordinating multiple roles and tasks. The lack of real-time visibility and integration with production planning systems further complicated efforts to maintain high product quality standards amidst frequent changeovers. The facility needed a solution to enhance flexibility, improve efficiency, and better align with rapidly changing market demands

The Key Collaboration Milestones:

01/2024
Analysis and Detailed Design
Comprehensive assessment and planning phase.
03/2024
Solution Configuration and Integration
Configured the solution and integrated with existing systems.
05/2024
Testing and Rollout
Conducted rigorous testing and initiated phased rollout.
08/2024
Go-Live
Full implementation of the solution.

Our solution

Aspecta partnered with the client to implement a digital Changeover Tool powered by Solvedio's cloud-based SaaS technology. This solution provided a centralized platform for managing every aspect of production line changeovers, with features including real-time tracking, role-based task assignments, and resource management.

The implementation led to:

- 30%

reduction in changeover times

+ 40%

improvement in visibility and coordination

+ 25%

better resource utilization

+ 20%

increase in production flexibility

These improvements empowered the company to maintain high product quality while adapting more quickly to market demands.

Changeover Image

The Changeover Tool implemented for this client consisted of six key functional elements:

1. Unified Digital Changeover Workspace

  • Centralized platform for managing all aspects of production line changeovers.
  • User-friendly interface is accessible across all production areas.
  • Role-based access control ensures appropriate permissions for different user types.

2. Changeover Process Management

  • Detailed workflow management for each changeover, including task sequencing and parallel processing capabilities.
  • Real-time tracking of changeover progress with completion percentage visualization.
  • Automated instructions and checklists tailored to each role involved in the changeover process.

3. Resource and Component Management

  • Each product requires comprehensive tracking of interchangeable parts, tools, and components.
  • Integration with external data sources for up-to-date production schedules and product information.
  • Efficient allocation and monitoring of resources during changeovers.

4. Role-Based Task Assignment

  • Specific interfaces and tasks for different roles (e.g., Toolmaker, Quality Control, Setter, SCM Handler).
  • Clear assignment of responsibilities and deadlines for each task.
  • A notification system will be used to ensure smooth handoffs between different roles and stages of the changeover proce

5. Reporting and Analytics

  • Comprehensive visualization of changeover processes and performance metrics.
  • Customizable reports and graphs for management oversight and decision-making.
  • Data-driven insights to support continuous improvement of changeover processes.

6. Integration and Security

  • Seamless integration with Azure Active Directory for user authentication and management.
  • Deployment as a multi-tenant SaaS solution within the client’s AWS cloud infrastructure.
  • Compliance with enterprise-level IT standards and rigorous security protocols.

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