Dana reduces
operator dependency
Managing multi-variant axle assembly
$2bn turnover, 5000 employees in Pune
A line with 200+ variants is managed by a system where operator dependency for critical operations is reduced to zero through detailed operator guidance and poka-yokes.
The Challenge
Manage a multi-variant axle assembly line with complex shim selection operations involving multiple, dynamic calculations.
How Did We Do This?
- By implementing ODIN Workstation on the entire line.
- By developing code and logic to transfer specific data from specific stations and calculate the shim values.
Benefits
- Customer was able to balance the line cycle time by analysing operator cycle time data.
- Customer used the data recorded for operations like tightening, leak testing and gauging to determine product quality trends.
Results
- ODIN Workstation made adding new variants easy, without touching the PLC.
- Dana was able to train new operators using the operator guidance system.
