CLIENT OVERVIEW
The client is a global technology company that designs, develops and manufactures software and hardware solutions to enable a safer, greener and more connected future of mobility. Their solutions help automotive OEMs around the world to create vehicles with advanced safety features, electrified architectures and intelligent connectivity.
BUSINESS REQUIREMENT
DELIVER A HIGH-QUALITY VISUAL PRODUCTION MONITORING FEATURE INSIDE THE PSD MODULE.
The client wanted Youngsoft to develop an AI application inside the PSD module to include the new feature of the Visual Production Monitoring process.
They wanted Youngsoft to deliver high quality Liferay modules for the implementation of this Visual Production Monitoring Feature. The Visual Production Monitoring system is a visual management system that helps to monitor production processes by signaling when there is an issue in the production cell. The system consists of lights (red, yellow, green) and is triggered when a shop floor worker detects a problem, such as quality issue, missing components (PC&L), machine failure (maintenance).
THE SOLUTION
AN END-TO-END VISUAL PRODUCTION MONITORING PLATFORM FOR THE SHOP FLOOR.
The Youngsoft Team implemented a global configuration module for SuperAdmin users to manage competencies. This would allow adding, editing, or removing competencies, icons, and colors based on business needs across all production sites.
The Youngsoft Team Provided Create, Read, Update, and Delete (CRUD) functionality in the Admin interface for competencies. These competencies can include support groups like Maintenance, PC&L, etc., and be dynamically updated at a global level.
Design an Admin area where severity levels (e.g., Severity 1: Full Stop, Severity 2: Degradation, Severity 3: No Stop) can be created and managed. These levels will be used by operators to categorize the seriousness of the issue.
The Youngsoft Team Implemented a step-by-step workflow for the Visual Production Monitoring system: “Normal Operation” (normal operations), “Issue Detected” (issue detected), and “Issue Assisted” (issue being handled). Operators will trigger changes through the user interface, updating the Visual Production Monitoring status.
Created a user-friendly, interactive UI for operators on the Cell monitor. This interface should display Visual Production Monitoring status using color-coded icons (green, red, yellow) representing different issue states.
Operators will select the appropriate competency group to signal when an issue occurs. Once the competency is engaged, the status will change visually (e.g., from Red to Yellow) until the issue is resolved.
Track issue progression on the monitor. Once a competency resolves the issue, the status will be updated by the operator, reverting to the initial icon to show that the problem is solved.
SuperAdmins can apply changes across all sites, ensuring a consistent and manageable Visual Production Monitoring system. Changes made in one location should propagate globally.
OUTCOMES
MEASURABLE GAINS ACROSS EFFICIENCY, CONTROL AND VISIBILITY.
The new Visual Production Monitoring platform empowers operators, supervisors, and SuperAdmins with the tools needed to detect, escalate, and resolve production issues quickly.
Improved Efficiency in Competency Management
SuperAdmins can easily manage and configure competencies, ensuring that the right support groups (e.g., Maintenance, Logistics) are dynamically assigned and updated across all production sites.
Structured Andon Workflow
Operators can follow a clear, step-by-step Visual Production Monitoring workflow. This structure helps the team quickly identify issues, signal the correct competencies, and track the issue from detection through resolution.
Enhanced Control Over Competency Data
SuperAdmins can create, update, and remove competencies as needed, streamlining the workflow and ensuring that only the required groups are involved when an issue arises.
Real-time Visual Monitoring
The Cell monitor provides an intuitive, real-time visual management system. Operators and supervisors can easily track the current status of production lines and address problems without delay.
Dynamic Severity Management for Smarter Prioritization
By allowing severity levels to be defined and adjusted through the Admin area, the organization can better prioritize issues based on their impact on production. This helps teams react more appropriately based on the urgency of the problem.
Accurate Assignment of Competency Groups
Operators can correctly identify and signal the required competency group, leading to faster resolution of production issues by notifying the appropriate teams (e.g., Maintenance, PC&L).
Streamlined Operator Actions
By limiting the operator’s interaction to the “Issue Detected” block, the process becomes less error-prone, as operators are guided step-by-step, ensuring they signal issues and their resolution in the correct order.
Centralized and Scalable Control
The ability to make global changes means that any update or modification to the Visual Production Monitoring system at one site will automatically apply to all other locations, ensuring consistency across the board.
Clear Communication of Issue Resolution
As the issue progresses from “Issue Detected” to “Issue Assisted,” and finally to resolution, the system provides clear visual feedback, allowing the team to stay informed about the current status of the problem.
Customization and Flexibility
The ability to customize icons and colors gives the organization the flexibility to tailor the Visual Production Monitoring system to their specific operational requirements, enhancing usability and visual clarity.
BENEFITS
SHORT- AND LONG-TERM BENEFITS OF A LEAN-READY VISUAL PRODUCTION MONITORING SYSTEM
Using the Visual Production Monitoring system in Lean manufacturing will yield many benefits both in the short and long term.
In the short-term, it provides
Short-term
Visibility & transparency in the production process- Increased productivity & efficiency
- Decreased waste
Long-term
- Reduced costs and downtime
- Enhanced value to the customer through better quality products
- Responsible operators who are accountable for the line running as efficiently and effectively as possible, empowering them to act when problems arise, rather than waiting for management.
- Long-term improvements to the production process
HIGHLIGHTS
Dynamic Competency Management
SuperAdmins can create, update, and manage competencies across all production sites.
Severity Levels
Configurable severity levels help prioritize issues based on their impact, from full stop to minor degradation.
Step-by-Step Workflow
Operators follow a guided process from issue detection (“Issue Detected”) to resolution (“Issue Assisted”).
Improved Efficiency
Faster problem resolution and reduced downtime due to clear workflows and prioritization.
Real-Time Visual Monitoring
The Cell monitor provides clear, real-time status updates on production lines.
Centralized Global Control
Changes made by SuperAdmins apply across all locations, ensuring consistency in operations.
Customization
Icons and colors can be adjusted to fit specific business requirements, improving visual clarity.
