CLIENT OVERVIEW
The client is a global manufacturer of advanced automotive components, specializing in high‑precision suspension and structural systems for high‑performance vehicle programs. Their facility required a modern, reliable, and scalable method of monitoring cell efficiency, closing visibility gaps, and enabling data‑driven decision‑making across machining, welding, and assembly operations.
BUSINESS CHALLENGE
Before implementing Insight+, several production cells lacked the real‑time insights and structured analytics needed to support continuous improvement.
Key Challenges Included:
- Manual, inconsistent data collection
- Limited visibility into production quality
- Difficulty identifying and analyzing downtime causes
- Siloed reporting requiring manual effort
- No unified OEE methodology across production areas
- No ability to compare SKU‑level performance
The organization needed an automated, standardized, and scalable platform to unify operational data and improve accuracy, accountability, and efficiency.
SOLUTION: Insight+ OEE & Performance Management Platform
Actemium implemented Insight+, a modular OEE and performance platform built on the Ignition industrial framework. This delivered a centralized, automated system for tracking and visualizing performance across machining and assembly operations.
Key Capabilities Delivered
1. Automated, High-Resolution Data Collection
Insight+ captured real‑time machine data and operator‑entered information, including:
- Machine states and fault signals
- Production counts
- Operator‑classified downtime events
- Cycle‑based throughput metrics
This created a trusted, high‑quality data foundation for accurate OEE visibility.
2. Customized Dashboards & Visualization
Insight+ provided role‑specific dashboards enabling:
- Live machining and assembly overviews
- KPI-driven widgets created by supervisors and engineers
- Shift performance summaries
- Real‑time OEE (availability, performance, quality)
The consistent UI empowered operators, technicians, and supervisors to make data-driven decisions.
3. Structured Downtime Classification & Loss Tracking
Operators recorded downtime reasons directly in Insight+, transforming raw stoppages into structured loss insights. This enabled:
- Precise downtime attribution
- Identification of chronic issues
- Clear views of top losses by shift, cell, and SKU
4. SKU Metadata Integration
Insight+ integrated the client’s product‑specific metadata:
- Target cycle times
- Expected throughput rates
- Product identifiers
This supported accurate benchmarking across product variants and improved traceability for quality programs.
5. Power BI Reporting Integration
Insight+ served as a rich data source for fully automated Power BI reporting, enabling:
- Weekly and monthly OEE trends
- Shift‑based analysis
- Performance comparisons by product family
- Long‑term equipment reliability insights
OUTCOMES & BENEFITS
1. Real-Time Operational Visibility
Engineering, supervision, and CI teams gained immediate insight into production status, allowing rapid decision‑making and improved responsiveness.
2. Accurate OEE & Production Accountability
Automated data capture replaced manual tracking, improving OEE accuracy and establishing consistent KPI definitions across all shifts.
3. Stronger Continuous Improvement Culture
Insight+ now supports:
- Daily production huddles
- CI reviews and root‑cause investigations
- Engineering performance meetings
Everyone works from the same accurate, shared data.
4. Scalable Multi-Line Architecture
The system allows future expansion across additional equipment and facilities, supporting the client’s long‑term digital transformation strategy.
5. Future-Ready Digital Foundation
The platform positions the client for additional capabilities:
- Predictive maintenance
- Cloud‑based analytics
- Energy/resource monitoring
- Integration with ERP, CMMS, and quality systems
CONCLUSION
The implementation of Insight+ delivered accurate OEE tracking, structured downtime insights, and a unified data model for continuous improvement. The client now benefits from a modern, scalable, and future‑proof performance management system that enhances production efficiency and operational excellence.
