Smart Factory Construction and Advancement for an Automotive Parts Company

This is a case study of Impix's smart factory construction for automotive parts, which advanced real-time equipment interconnection and LOT tracking systems to improve quality and productivity based on manufacturing data.



1. Pain Point 

Manufacturing Data and System Aspects 

- Operational management data is being accumulated, but there is a lack of direction on how to utilize the stored manufacturing data.

- There is a need to evaluate the current factory level and consider future predictive applications based on the manufacturing data held by each manufacturing company.

- The need to enhance the manufacturing management system and ensure the usability of manufacturing data has emerged as a key challenge.

Equipment and Infrastructure Aspects

- Due to the increasing demand for automotive batteries, there is a shortage of production capacity in existing factories.

- Due to insufficient capacity, the factory has been expanded, resulting in an increase in equipment scale.

- There is a need to upgrade the system based on equipment data collection.

Human resources and operations

- With the relocation and expansion of the factory, there is a need to improve the work efficiency of on-site personnel.

2. Smart factory construction details

Manufacturing management system upgrade

- Integration of sales, production, purchasing, materials, outsourced equipment, and management through the upgrading of the manufacturing management system established as a basic project.  

- Quality, process, and analysis through OPC-UA real-time equipment data collection.  

- Operation of a data utilization system that stores manufacturing data generated during the process of various equipment devices on an integrated server for monitoring and management.

Quality and Process Analysis

- Establish indicators such as process-specific production performance analysis, quality standard management by production item, process capability analysis, and quality standard deviation analysis.

LOT-based History Tracking Management

 

3. Effects of Smart Factory Construction

Before Implementation

- Process defect rate: 10,277 ppm 

- Production volume per hour: 1,500 units 

After Implementation

- Process defect rate: 5,650 ppm 

- Production volume per hour: 1,880 units