Driving excellence: A drop in changeover downtime in automotive manufacturing

The Challenge

A major automotive supplier struggled with excessive changeover downtime that significantly impacted their Overall Equipment Efficiency (OEE). Seeking to enhance manufacturing efficiency and address these persistent downtime issues, the company needed an innovative solution that could deliver measurable improvements to their production processes.

The Solution

The automotive supplier implemented Milacron M-Powered, a comprehensive cloud solution powered by ei³ that extends beyond conventional Manufacturing Executing Systems (MES). This platform combines advanced process analytics, remote field service capabilities, and predictive maintenance to optimize manufacturing operations.

The implementation focused on three key areas to address the supplier's specific downtime challenges:

• Advanced Analytics and Remote Service: Milacron M-Powered delivered real-time production insights, enabling effective management of production schedules, customized downtime tracking, and optimized changeover planning.

• Enhanced Team Coordination: The solution provided immediate access to critical information on jobs, machine states, and schedules, significantly improving team coordination and reducing downtime across operations.

• Daily Reporting for Productivity: Team leads received daily reports through the M-Powered Service Portal, highlighting improvements in productivity, speed, quality, and customer satisfaction metrics.

Results

• 64% Reduction in Changeover Downtime: Over a 20-month period, Milacron M-Powered systematically addressed machine improvements while minimizing unassigned and scheduled downtime instances.

• 10% Increase in Overall Equipment Efficiency: The implementation proved transformative for the automotive supplier, marking a significant milestone in their operational excellence journey.