The average recall creates a $4.1B loss to a company’s bottom line. It costs an average of $100M in value for four weeks of excess inventory build up. Misplaced or idle tools leave room for an average 30% increase in Overall Equipment Efficiency (OEE).

A Closer Look: Manufacturing Case Studies

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Challenge

Inaccuracy of parts and containers delivered from dock to plant lead to production delays.
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Solution

End-to-end continuous visibility of inventory helps optimize work-in-process (WIP) and production scheduling.
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Results

Efficient production scheduling with 99% inventory accuracy (parts & containers) and 80% reduction in production downtime.

Customer: Tier one automotive supplier has several overlapping opportunities for operational efficiency that could save them $50-$100M dollars/year with greater tracking and coordination technology.

Critical Tracking Points

  1. Distributed Container Assets: Tracking 1-2 million returnable containers that cost $200 each are in circulation across 136 facilities throughout the U.S. at any one time. Approximately 10% loss of visibility happens once containers go to automotive OEM. Optimizing trailer and shuttle use for increased production and improved customer delivery times.
  2. Large Tools: Locating and retrieving large tools that get shipped to OEMs for manufacturing using their parts. The tools cost from $0.5M to $1M and are scattered between the manufacturer’s or OEM’s facility. A missing tool or asset impacts the bottom line since tools are not readily available or cannot fulfill OEM’s order requirements for tooling.
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Summary Of Tracking Needs

The company wants to track containers and returnable bins across several customer supply chains. Other priorities include optimizing trailer and shuttle use between plants, tracking internal forklifts as well as locating and retrieving expensive tools.

Cloudleaf Solution

Traceability of valuable tools to minimize loss and improve order fulfillment for OEMs improves visibility and optimization for shuttles and forklifts, as well as cycle time for loading and unloading. Efficient movement of storage bins and reduction of excess bin inventory so they know how many empties they have and are available for use.

Customer: Steel manufacturer needs better visibility on transportation of molten metal to reduce dwell times, which can create excessive material waste.

Critical Tracking Points

  1. The Foundry: Moving molten metal from foundry to stamping facility (intra-plant move) in rail cars/torpedo carts. The carts move slowly and there is a need to know when they leave the foundry so that they can plan accordingly at the plant.
  2. The Factory: The company wants to manage dwell time so that they can monitor the condition of molten metal, which goes bad if it stays out too long. Metal hardens and becomes a total loss for both the metal and the cart it is in.
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Summary of Tracking Needs

Cart movement to predict the location of molten metal and track dwell times to reduce material waste and increase productivity.

Cloudleaf Solution

Sensors provide the ability to track the location of the carts for better production planning. An alert is sent once molten metal reaches its dwell threshold. The result has been 90% improvements in production scheduling and $10-$20M in annual savings due to material loss of hardened liquid iron.

Automotive Container Tracking Across Distributed Supply Chain

Container Storage Area at Supplier Manufacturing Facility

Containers Tracked In Transit

Receiving Area at Automotive OEM

Shipping Area at Automotive OEM

Containers Tracked In Transit

Container Storage Area at Supplier Retrofitting Facility

Real-Time Manufacturing Insights

Cloudleaf Savannah™ is where your data comes alive. Check the pulse of your business anytime through a variety of dashboards. Monitor location and condition of tools, equipment and assets. Generate alerts or take corrective actions.

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Resources

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Cloudleaf CEO On The Peggy Smedley Show: Common Supply Chain Challenges
Cloudleaf Is an “Innovation Leader” Finalist in the Automotive Logistics Awards
Logistics IT: Is There an App for That?
Cloudleaf’s Connectivity Devices and Cloud-Native Apps Make IIoT a Breeze
Blockchain is the New Supply Chain
Smart-Enabling Each Link in a Next-Gen Supply Chain
Video
The Next Manufacturing Revolution Is Here
Video
Smart Manufacturing Innovation
Cloudleaf CEO On The Peggy Smedley Show: Common Supply Chain Challenges

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Video
The Next Manufacturing Revolution Is Here
Video
Smart Manufacturing Innovation
Video
Industry 4.0 in the Volkswagen Group
Cloudleaf Is an “Innovation Leader” Finalist in the Automotive Logistics Awards
Logistics IT: Is There an App for That?
Cloudleaf’s Connectivity Devices and Cloud-Native Apps Make IIoT a Breeze
Blockchain is the New Supply Chain
Smart-Enabling Each Link in a Next-Gen Supply Chain

No download resources added at the moment.

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