Application

Short Description

Lean Manufacturing Engineering

Combines all processes and applications engineers require and like to convert innovtion and product design fast into streamlined manufacturing operations.

Lean Process & SOE Design

Rapid creation, maintenance and optimization of work information and sequences. Fast 'drag & drop' assignment of materials, tools and qualification requirements to processes and integration of line logistics and line planning. Integrated FMEA, quality information, Lean Design, Engineering Change Management as well as visual workload balancing ensure efficient planning for smooth, high quality manufacturing operations.

Visual Instruction Design

Fast 'drag & drop' supported creation and maintenance of visual instructions for assembly and quality processes, but also set up, change over and packaging processes. Efficient support by library integration allows to create visual process drawings and combinations of drawings, photos and streaming video extremely fast, reducing time drastically. Visual instructions can be electronically distributed instantly on time or scheduled to any workstation.

Process Management Matrix

Identification of similarities in manufacturing and supply processes as well as rapid maintenance of process cycle times and sequence of events. Based on manufacturing families all process structures are displayed in a matrix. Incorporated are simple maintenance of cycle times of several assemblies and products simulaniously and simple 'drag & drop' assignment of all related objects.

Lean Assembly Line Design

Design and calculation of lean assembly lines and line key performance information and includes fast 'drag & drop' assignment of products and sub-assemblies. Simulation and interactive workload and capacity planning. Integrated process and component mapping optimize line logistics and process flow. The integrated color-coded 'early warning work balance portal' provides information about potential or actual bottlenecks and avoidable WIP inventory.

Component Management Matrix

Identification of similar component usage and comparison of multiple products in matrix display. Verification of common and special material with quantity matrix simplyfies preparation and optimization of supply processes. Statistics show degree of commonality within multiple products, interactive functions allow verification and definition of Kanban as supply strategy.

Set up and Change Over Management Matrix

Definition of set up and change over processes and times in matrix overview. Processes, set up and change over times can be maintained for products and sub-assemblies at any level of detail supporting 'Single Minute Exchange of Dies' (SMED). All information is saved as process structures enabling all functionality of sequence of event design including visual set up and change over instructions and electronic distribution to shop floor operations and maintenance departments.

Component Change Over Matrix

Defines the change over requirements for materials at assembly lines. Determines how many materials are to be exchanged switching from one product to another. The overview is displayed as a matrix, showing common part and exclusive part usage as well as the number of change over materials.

Tact Time Matrix

Definition of tact times in matrix display. Tact times can be defined for products, assembly lines and operations. Interactive functions allow fast and comprehensive definition and maintenance.

Process Change Management

Systematic integration of continuous improvement (Kaizen) for all shop floor and supply processes. Simple and fast reporting of suggestions and visual definition allow electronic information flowing back to enginnering departments. Leveraging improvement suggestions and solid expertise and experience bottom-up in all processes.

Flexible Logistics & Value Chain Planning

Combines all processes and applications for line side material and logistics planning as well as Kanban Management and Early Warning applications 

Supply Point Management

Definition of line side supply points and supply areas, from warehouses and material buffer zones to supply points at assembly lines. Support of space calculation requirements and simple 'drag  & drop' assignment of supply points, racks and any supply point equipment.

Supply Synchronization & Change Impact Management

Demand-based synchronization of materials and supply to assembly lines and workstations for faster access and constant material availability at lowest inventory levels. Simple 'drag & drop' support for rapid assignment of materials to supply points and line side. A color-code supported 'early warning portal' provides instant information about changes in product demand or due to engineering change management. It enables instant information flow and fast adjustment to changing supply situations, and includes all required Kanban management and adjustment functions.

Supply Cycle Management

Comprehensive management of Kanban and other supply strategies. Demand-based calculation and monitoring of Kanban cycles and optimizing line side inventory levels. An 'early warning portal' and comprehensive demand projection and simulation allows the identificationof future demand changes early, to manage it's impact and to avoid material shortage and supply issues.

Flexible Workforce Management

Combines all processes and applications required for personnel and resource management, resource planning, experience and training tracking, as well as other functions to create a flexible workforce.

Qualification Management

Definition of qualifications and qualification levels for all personnel, specifically for shop floor personnel. Integrated information about certifications and even measured practical experience at workstations and processes. Simple 'drag & drop' assignment of certifications and personnel simlyfies a systematic maintenance of information.

Qualification Matrix

Fast overview and maintenance of personnel and workstation qualifications in matrix overviews. 'Early warning' functions provide alerts for potenial qualification issues and training needs. Simulation of attendance and absence allows verification of potential qualification botttlenecks at workstations and timeframes. Also the qualification matrix shows the degree of flexibility at workstations and supports training planning and measures to increase flexibility through-out shop floor operations. Besides show floor operations also qualification requirements for administrative workplaces can be managed with this application.

Flexible Workforce Planning

This interactive application provides a powerful tool for fast and efficient demand-based planning of personnel for manufacturing operations. Shift planning can be prepared ensuring matching qualifications and availability of personnel, provides color-coded 'early warning' and completeness checks. All functions are supported by simply 'drag & drop' functionality. Potential bottlenecks are immediately visible and all workstations can be planned efficiently and fast.

Manufacturing Scheduling

'Drag & drop' supported customer, production, stock and rework planning with weekly and daily planning buckets. The application provides color-code supported interactive capacity mapping and various planning strategies. Orders can be planned manually or automatically, enabling planners to assign fast, with 'drag & drop' and oversee all orders and times. Required resources and work time can be determined demand-based and flexible work time methods are supported dynamically.

Visual Manufacturing Operations

Combines all processes and applications for visual manufacturing operations and tracking of products, supporting Zero Defect and Zero Tolerance Strategies

Manufacturing Order Scheduling

'Drag & drop' supported customer, production, stock and rework planning with weekly and daily planning buckets. The application provides color-code supported interactive capacity mapping and various planning strategies. Orders can be planned manually or automatically, enabling planners to assign fast, with 'drag & drop' and oversee all orders and times. Required resources and work time can be determined demand-based and flexible work time methods are supported dynamically.

Fast Manufacturing Scheduling

'Drag & drop' supported customer, production, stock and rework planning with weekly and daily planning buckets. The application provides color-code supported interactive capacity mapping and various planning strategies. Orders can be planned manually or automatically, enabling planners to assign fast, with 'drag & drop' and oversee all orders and times. Required resources and work time can be determined demand-based and flexible work time methods are supported dynamically.

Visual Factory Process Portal

'Pictures tell more than 1000 words...' Interactive visual assembly and quality instructions, with 'point & click' simplicity and interactive applications provide not only assembly guidance, but convert workstations into the information center for productivity and quality for any modern manufacturing plant. Integrated applications let information flow instantly and build the basis for Total Quality and Total Performance.

Interactive Total Quality Control

Simple 'point & click' based interactive tracking toolset for all assemblies and materials ensuring true support of 'Total Quality' and 'Zero Defect' strategies. Fast and detailed reporting with or without pre-defined defect codes enable immediate information flow. 'Early warning portals' with integrated 'First Passed Yield' calculations ensure excellent manufacturing and supplier quality. 'Visual TQC' even allows reporting of quality issues with visual marks and coordinates based on images and photos of assmblies and materials.

Interactive Through Put Control

Integrated automatic performance control for workstations. Consumption and through-put confirmation trigger real-time information flow to 'early warning portals' with interactive 'Overall Equipment Efficiency' (OEE) reporting. Even automatic information collection via Equipment PLCs is supported in order to reduce efforts, while increasing information availability significantly.

Interactive Workstation Control

'Point & click' based interactive, quick and simple on-line reporting and real-time information flow for any workstation issues. Any machine, equipment, material supply or personnel issue is being reported quickly, and information flows to the people who need to know: Logistics, Maintenance, and Management. 'Early warning portals' show color-coded where potential or actual issues arise and lead to instant actions, eliminating issues not only fast, but systematically, ensuring 'Total Performance' and highest 'Overall Equipment Efficiency' (OEE).

Interactive Supply Execution Control

Interactive 'point & click' based supply execution via electronic signals. Automatic Kanban supply by electronic signals, controlled by 'early warning portals' and electronic Kanban supply boards. The application ensures highest material availability at the point of use and all other supply points as well as optimized smooth material flow without issues and material shortages.

Interactive Metrics & Quality Data Control

Comprehensive, but fast capturing of product metrics, process parameters, such as test results, measurements, check lists, target and actual values, calibration and results of manufacturing processes. All product, process and environment information as well as set up and change over parameters are captured and guarantee fast flawless and complete traceability at any time. Even test equipment can be connected and may provide comprehensive test results automatically.

Interactive Serial Number Control

The application provides simple bar code supported reporting for material serial numbers and ensures strategic traceability of product and material information. Color-coded symbols display required trace actions and serial number logic checks exclude reporting errors.

Interactive Lot Control

The application provides simple bar code supported reporting for material lot numbers and ensures strategic traceability of product and material information. Color-coded symbols display required trace actions and lot number logic checks exclude reporting errors. 'Full/ empty' processing simplyfies reporting and handling.

Interactive Process Change Control/ Kaizen

Simple 'point & click' based electronic support for 'Continuous Improvement' and 'Kaizen' initiatives. Immediate electronic information flow ensures smart ideas and suggestions in regards to manufacturing and supply opertions arrive where they can be turned into efficient solutions, systematically.

Interactive Rework Management

All required rework processes can be processed with visual guidance, integrated in Visual Factory Portal functionality. Rework times and exchange of components are captured for full traceability. Rework can be performed at the same workstation, at workstations earlier in the process or at specific rework stations. After processing, assemblies can be reintroduced in assembly operations smoothly, while all rework information is available real-time.

Interactive Material Verification

Bar code based pick and assembly control with color-coded signals. This electronic material identification allows correct pick and assembly of correct materials, especially if many 'look alike' materials for variances of the porduct are available at the workstation or supply point. Integration of 'pick-to-light' functions increase product quality and processes.

Interactive Change Introduction Control

Visual display of changes and change management information ensures timely and complete introduction of engineering changes at any workstation. Clearly understandable visual information reduces administrative efforts and communication needs.

Visual Packaging Portal

Visual instructions for packaging processes and operations, including all interactive functionality of 'Visual Factory Process Portal' applications, focusing on packaging processes. All packaging instructions and requirements are displayed and enable packing assemblies and products according to customer specifications.

Process Tracking Portal

Application for high volume manufacturing processes providing full traceability of manufacturing processes and interactive functions with minimum efforts and hardware. Allows reporting and tracking of quality information as well as material lots for manufacturing areas without system support at all workstations. Stations at the end of assembly lines and processes or at strategic locations fullfill the work of stations earlier in the process.

Manufacturing Action Control

The application enables fast reporting of workstation and supply issues of any type. It provides systematic supply of materials and ensures highest productivity at all workstations and supply points. All information is automatically real-time distributed to all required areas, departments and personnel responsible, and is available in 'early warning' and 'manufacturing portals'.

Performance & Efficiency Data Control

Simple and fast reporting of manufacturing results and developments at any time or at the end of shifts. Automatic real-time information flow of through-put, quality and 'First Passed Yield' provides corresponding 'FPY' and 'OEE' information in all manufacturing portals.

Andon Board

Providing manufacturing performance and quality information on large flat screen monitors visible on the shop floor. Color-coded key performance indicators of assembly lines and workstations are visible for everyone in manufacturing areas. Real-time updated information about manufacturing progress and status, quality issues and downtime reasons.

Mobile High Volume Manufacturing Portal

Process control, material control and supply as well as visual instructions with bar code integrated mobile equipment, wherever flexibility and mobility is required. All applications related to Visual Factory Process Portal are Pocket PC and PDA enabled.

Cyber Visual Factory Portal (research project)

'Touching the future...'. Visual instructions projected into your eyes with high tech eye glasses and state of the art laser technology. For processes without PC and monitor support, handsfree solutions, speech enabled interactive applications. Coming soon...

Smart Factory Integration

Integrates factory technology from 'Pick-to-Light' and 'Andon Boards' to 'Programmable Logic Controllers' for Equipment Information. Test stations can be connected to provide test results and information for full traceability and transparency.

Total Quality Management

Combines all processes and applications supporting 'Zero Defect' and 'Total Quality Management'. Pro-active 'early warning' for all quality relevant processes and actions.

Pro-active Manufacturing TQM Monitoring

'Early warning' and pro-active monitoring of manufacturing quality and characteristics for products, sub-assemblies and materials in manufacturing processes. Provides color-coded information of TQM constraints and quality issues, real-time, early enough to react instantly. Contraints can be pre-defined in order to show significant quality deviations immediately and color-coded.

Pro-active Supplier TQM Monitoring

'Early warning' and pro-active monitoring of material quality and characteristics for all materials coming from suppliers and supplying plants or sub-contractors. Provides color-coded information of TQM constraints and quality issues, real-time, early enough to react instantly. Contraints can be pre-defined in order to show significant quality deviations immediately and color -coded.

In-Process Quality Management

Strategic support of manufacturing quality inspection processes and fast reporting of detailed quality information for materials, products and sub-assemblies. Quality deviations, with 'Interactive TQC' reported, can be retrieved by quality inspectors or added directly and real-time. Fast verification and maintenance or potential correction of quality results ensure a quick and comprehensive quality data collection. All information is transparent and available in 'early warning portals' as 'First Passed Yield' and material quality overviews.

Total Quality Management Reporting

Comprehensive quality reports and statistics, 'First Passed Yield' and material quality key indicators, supported with download options to MS Excel.

Total Performance Management

Combines all processes and applications ensuring highest performance of all manufacturing and plant operations, supporting 'Zero Tolerance' and 'Total Performance', systematically.

Pro-active Workstation Issue Monitoring

'Early warning' and pro-active monitoring portals react directly to real-time information from manufacturing areas, machine and equipment, material flow and personnel issues. Potential or actual issues are real-time visible and can be processed interactively. Color-coded signals display priorities and actions. All times, including reaction and processing times are captured automatically in order to ensure systematic elimination of issues and support continuous improvement in all plant operations. This powerful application also enables continuous improvement teams to analyse symptoms, reasons, times and actions.

Pro-active Machine & Equipment Monitoring

'Early warning portal' for corrective maintenance departments for immediate reaction and elimination of manufacturing issues. All potential and actual issues of machines and equipment as well as tools and fixtures are displayed color-coded according to their priorities. All activities and follow-up actons can be planned, controlled and managed with 'Action Management' functions.

Pro-active Line Material Monitoring

'Early warning portal' for logistics and line side operations management for immediate reaction and elimination of supply and material issues. All potential and actual issues of materials and supply are displayed color-coded according to their priorities. All activities and follow-up actons can be planned, controlled and managed with 'Action Management' functions.

Pro-active System & Technology Monitoring

'Early warning portal' for System and Technology departments for immediate reaction and elimination of technical and system issues. All potential and actual issues of IT equipment and technology are displayed color-coded according to their priorities. All activities and follow-up actons can be planned, controlled and managed with 'Action Management' functions.

Pro-active Resource Monitoring

'Early warning portal' for personnel responsible and supervisors for immediate reaction and elimination of personnel issues. All potential and actual issues of personnel are displayed color-coded according to their priorities. All activities and follow-up actons can be planned, controlled and managed with 'Action Management' functions.

Manufacturing Information Center

Combines all processes, applications and information portals for consolidated information through-out the entire plant operations, Monitoring performance and quality

Pro-active Plant Performance & Efficiency Dashboard

Real-time information flow of all fully integrated applications in manufacturing, quality and logistics enable line managers, manufacturing and plant managers to immediately access all information required to actively steer manufacturing and plant operations. Highest transparency in 'Overall Equipment Efficiency' (OEE), 'First Passed Yield' (FPY), material and supply quality, issues and downtimes, order and delivery situation and production linearity, visible in a real-time performance dashboard.

Manufacturing Operations Portal

Provides comprehensive overview about all manufacturing operations. Real-time 'OEE' and 'FPY' as well as its development, linearity and on-time achievements, line side information, personnel, issue management, quality, and 'Lean Manufacturing' design. All information is being consolidated real-time, without manual efforts and activities - on plant level.

Assembly Line Portal

Provides comprehensive overview about assembly line operations. Real-time 'OEE' and 'FPY' as well as its development, linearity and on-time achievements, line side information, personnel, issue management, quality, and 'Lean Manufacturing' design. All information is being consolidated real-time, without manual efforts and activities - on assembly line level.

Workstation Portal

Provides comprehensive overview about assembly line operations. Real-time 'OEE' and 'FPY' as well as its development, linearity and on-time achievements, line side information, personnel, issue management, quality, and 'Lean Manufacturing' design. All information is being consolidated real-time, without manual efforts and activities - on workstation level.

Machine & Equipment Portal

Provides all information, consolidated reports and overview about individual machines and equipment.

Product & Process Metrics & Quality Portal

This application is fully integrated in 'Visual Manufacturing Operations' and provides comprehensive information about products, material, lot and serial number usage, manufacturing processes and environment, quality and metrics, as well as equipment and change over parameters, calibration and any other parameter or value product and process related, Full tracability at your fingertips. It offers impact identification and display of impact on customer orders, finished goods, WIP and raw material and allows blocking of inventory or 'call back' of the lowest required quantities. Extensive 'where used' functions ensure comprehensive research and fast reaction.

Report Dashboard

This applications enables you to analsyse all performance related information in detail. Key performance indicators from manufacturing performance and overall equipment efficiency (OEE), manufacturing and logistics process issues and downtimes to quality and through-put information.

Lean Operations Optimization Portal

The 'Lean Operations Optimization Portal' supports all lean initiatives strategically and it provides comprehensive analysis tools for manufacturing, quality and logistics processes. It contains cycle time analysis and management, Top 10 and Top NN overviews for quality, suppliers, processes and many more functions for continuous improvement of all lean processes. All 'Lean Manufacturing' calculations are processed real-time and interactively.

Supply Chain & Logistics Management

Combining all processes and applications of logistics and supply chain operations.

Value Chain & Logistics Portal

Comprehensive information portal for all material and product related information, including master and process infromation. It contains information about suppliers, points of use, points of supply, supply cycles, products and materials, demand and consumption development, control and process parameters. All information is automatically consolidated and conveniently displayed.

Pro-active Material Availability Monitoring

Comprehensive 'early warning portal' for material availability and supply chain tracking. Demand, manufacturing planning and inventory as well as supply chain situation and status are displayed in time horizons, identifying potential material shortages and supply issues early enough to react. The portal identifies supply issues and displays color-coded if and when issues may arise, long before seriously disturbing plant operations.

Bin & Packaging Tracking Management

Simple tracking of empty bins and packaging circulating between plant and suppliers. Bins can be identified, materials can be assigned and bins can be moved from location to location, supplier, warehouse, manufacturing with simple 'drag & drop'.  

Pro-active Line Logistics Monitoring

'Early warning' and pro-active monitoring of line logistics operations, including Kanban cycle monitoring and pro-active line side material monitoring.

Factory Inventory Management

Usually ERP Systems manage inventory and CellFusion applications are integrating into these systems. However, in case such systems are not in place or too 'heavy' to handle lean shop floor inventory operations, this application can be used as a 'light-weight' solution. Factory inventory, from raw material and work in process to finsihed goods, can be managed and controlled.

Pro-active Kanban Board & Logistics Monitoring

All supply signals can be displayed according to their priorities with comprehensive electronic Kanban board functionality. The Kanban board can be displayed with different views, by source or by demand, and it shows demand and supply signals color-coded for individual materials and assemblies. Processing is done fast and simple, with interactive functions providing action and comprehensive overview and process control.

Integration

All applications are integrated in a variety of third-party applications

SAP Integration

Business processes are always integrated and vertically organized. This means systems and applications need to be vertically integrated as well. Due to these needs CellFusion applications are fully real-time integrated in ERP/ SAP applications, wherever this integration is beneficial and required. SAP integration is made possible due to fact that both companies, SAP and CellFusion, share an open platform and technology. CellFusion's SnAP Connector Cell Technology connects to SAP's 'BAPI' and 'RFC' as well as the new 'Netweaver' technology real-time and is fully integrating modern applications.

Graphics and Drawing Applications

All leading graphics and drawing applications are fully integrated in applications such as Process & SOE Design, Visual Instruction Design, and others. This includes standard applications like IGrafx, Micrografx products, IsoDraw, Corel Draw, MS PowerPoint and others.

Microsoft Excel

Excel has been integrated in various applications to enable data exchange, import and export functions, download of entire data areas or specific information. Besides this CellFusion's 'drag & drop' technology has been extended to offer simple 'copy & paste' functionality to quickly transfer data and information.

Process Support Management

Supporting processes and applications 

Plant Structure & Workplace Management

This application allows to structure all departments based on organizational charts and builds the central application to set up not only department structures, but assembly lines, workstations, machines, workplaces, supply points and any kind of structural object required in a plant. It allows to assign personnel and workplaces and to define responsibilities for any structural object.

Action Management

This is the central application for all workflow, information flow, alert management and actions that are assigned to responsible personnel. Here all information flow is organized, work is distributed dependent on individual responsibilites and based on events in processes.

Personnel & Responsibility Management

Personnel information can be maintained fast in this application, it builds the basis for several other applications, from qualification matrix to responsibility management. Personnel information can be entered, CellFusion user information and authorizations are defined here.

Work Time Management

Worktime, Shifts and shift profiles can be maintained in this application. Shift information is used in several other applications.

Multiple Assignment Management

A reusable application to build and form any kind of groups, product groups, material groups, assembly line groups, workstation groups, personnel, equipment or others. The assignment is done extremely fast for multiple objects utilizing drag and drop technology.

Failure & Issue Management

Potential failures and issues can be defined here, with severity, impact, escalation and other parameters

Constraints Management

All constraints can be defined centrally, for TQC, OEE, TPM, and others. Color codes can be defined showing and alerting in statistics and list overviews. 

Location Access Management

Simple and fast access management to plants and locations, for staff, visitors, staff of other plants and whoever may need to register when entering a location. It is not only used to register people, but also to provide full completeness checks for assembly line staff and other requirements.

Mass Data Creator

Fast and simple import of data from external sources, simple copy and paste functionality from Excel sheets, quick data loading.