Case Studies
Central Motor Wheel of America – 7.5 Million Wheels Per Year
Central Motor Wheel of America is a Japanese automotive supplier of both steel and aluminum wheels. There are two plants in Paris, Kentucky that produce the bulk of wheels for the Toyota Georgetown assembly plant as well as other brands. These plants have been using Mainsaver since the mid nineties for corrective and preventive maintenance, inventory and purchasing.
The operations of Central Motor Wheel of America are divided among two separate plants. Central Light Alloy produces cast aluminum wheels while Central Manufacturing Corporation produces steel wheels. Each plant has their own maintenance and supply chain departments. In 2006, the maintenance organizations decided to improve the utilization of Mainsaver as part of their Equipment Assurance Program which aims to reduce equipment downtime.
Working with a Mainsaver project manager, a plan was developed with the following milestones;
1. Interface the Mainsaver inventory module to a Kardex Titan vertical parts retrieval tower
2. Since the two plants operate autonomous, separate the single Mainsaver database into two database, one for each plant.
3. Add the Mainsaver Interconnect module to allow each separate plant to search part inventories and request parts transfer of common parts.
4. Implement MobileMainsaver on wireless PDA devices to allow maintenance personnel to complete and enter work orders remotely
5. Implement bar coding as an alternative way to issue parts using a wireless scanner
6. Training of maintenance associates on Mainsaver
7. Develop KPI Reports to track maintenance effectiveness
Titan Interface
Maintenance Associate can browse and issue parts through Mainsaver. When the desired part is located in the database, Mainsaver will retrieve the correct shelf in the Titan parts retrieval tower. Laminated Kanban cards are also kept on the shelves to aid in replenishment of inventory.
Mainsaver workstation next to Titan system.
Kanban ticket may be scanned for issue or entry on a purchase requisition.
Mainsaver Interconnect
Although the CMC plant is mainly a stamping and roll forming operation and CLA is a casting and machining operation, there are always maintenance, repair and operations parts that are common. Mainsaver Interconnect provides users with a search engine to find parts in the other plant and request a transfer. This feature will help to reduce downtime by providing an alternate source for critical repair parts.
Here the user is searching the CMC database for a 6206 bearing.
KPI Reports
A basic set of Key Performance Indicator reports were developed. One that is used most common is a simple listing of all past due work orders.
Downtime has been trending downward after the Mainsaver enhancements. Maintenance Associates are better training on the software and the Maintenance Coordinators are doing a better job of managing pending work. The inventory is being managed better resulting is fewer stockouts. |
