Optimizing batches and sequence dependency can have dramatic impacts on the smoothness of flow. In some situations, setup times can range from 20 minutes to 8 hours while production runs can be as short as 30 seconds yet as long as 2 days. Firstly, many processes involve specific resources which can potentially become bottlenecks due to lengthy setup times. Much of the nature of Contour’s manufacturing adds to the innate planning and scheduling challenges that already exist. It is no wonder that Hancock says that success depends very much on ensuring the right component for the right product is at the right place at the right time with the right resource being available to action the next step. In terms of time scales, turn around per unit is approximately 2 weeks although as will be already apparent, there is a huge amount of sequence dependency involved during this process. Furthermore, there are various stages of sub assembly involved at different points in the manufacturing process before the final collection of parts and sub assemblies are dispatched to the main assembly site for completion.Īll this would be difficult enough to manage if each seat was standard but every airline requires different levels of customization to an order so in effect, each order is treated as unique although one which may use many existing part numbers. Quite often, the only Top Level Parts we are supplied with is customer specific audio/visual equipment and actuation systems, although even here, if a customer has a deal with an existing supplier, we will have to use those supplied components.” All of the above is handled by over 40 CNC machine centres plus a range of further metal working cells, 6 vacuum forming areas, 10 fabrication related centers, and further departments dedicated to composites and electrics. “When we say we manufacture the vast majority of each seat, we are talking everything from every metal fixture and fitting, through to the majority of every molded part, most composite elements, the soft furnishings including leather, even the wiring harnesses that control the electrics. However, as Planning Manager Leyton Hancock explains, this barely describes the true complexity involved. Add to this the fact that Contour typically manufactures 200 seats per month with each seat costing up to £85k and the scale of the company’s production planning and scheduling becomes clear. In order to ensure the required levels of quality control, 70% of all components are manufactured in-house including 90% of all metal items. It therefore comes as no surprise that each seat comprises between three and four thousand top level parts from a range of almost 100,000. In addition to a multitude of seating and sleeping positions, each unit provides an array of audio visual possibilities as well as a growing number of communication options. Those fortunate enough to have flown First or even Business Class will appreciate that the word “seat” does not do justice to the modern travel environment such seating provides. When Contour needed to invest in upgrading its existing production planning and scheduling capabilities, it found the first class solution in Preactor. Serving the premium end of a market which already demands the most rigorous levels of quality, consistency and traceability requires absolute precision at every step of what is a highly complex manufacturing process. Headquartered in Cwmbran, Wales, the £100m turnover company employs 800 people across its 2 main sites which operate as a mini supply chain with the primary manufacturing and sub assembly business directly supplying the final assembly and sales business. Opcenter (Preactor) Advanced SchedulingĬontour Premium Aircraft Seating is one of the leading premium aircraft seating manufacturers in the world supplying to many leading international airlines.Advanced Planning & Scheduling (APS) Menu Toggle.
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