In the realm of automotive manufacturing, efficiency is paramount. One global giant in automobile seat cushion production faced significant challenges in meeting customer demands while maintaining cost-effectiveness. Employing a manual scheduling process with a mix of expertise and spreadsheets, they struggled with excessive mold changes, high overtime costs, and logistical bottlenecks.
Enter the game-changer: a collaborative effort with BBA. By integrating mathematical optimization with digital twin technology, the Company revolutionized the way they scheduled the production line. This innovative solution slashed costly mold changes by an impressive 62%, ensuring smooth operations and reduced downtime.
Moreover, the solution addressed on-time delivery concerns while maintaining optimal stock levels for each seat variant. The newfound efficiency not only cut an average of four overtime shifts per month, but also empowered schedulers to focus on long-term capacity planning.
This success story underscores the transformative power of technology in manufacturing. By embracing cutting-edge solutions, even the most complex challenges can be conquered, paving the way for a more streamlined, cost-effective future in automotive production. Click here for more information about this case study.