FORCAM Case Studies GKN Aerospace Achieves 20% Reduction in Operation Time with FORCAM FORCE

	GKN Aerospace Achieves 20% Reduction in Operation Time with FORCAM FORCE FORCAM

GKN Aerospace Achieves 20% Reduction in Operation Time with FORCAM FORCE

FORCAM

Technology Category	Functional Applications - Manufacturing Execution Systems (MES) Analytics & Modeling - Predictive Analytics Application Infrastructure & Middleware - Data Visualization
Applicable Industries	Aerospace
Applicable Functions	Process Manufacturing Maintenance Quality Assurance
Use Cases	Machine Condition Monitoring Predictive Maintenance Energy Management System Process Control & Optimization Real-Time Location System (RTLS)
Services	System Integration Data Science Services Training
Challenge	GKN Aerospace, a leading aerospace supplier, faced the challenge of improving manufacturing productivity in a low-volume, high-mix environment. The company needed a solution to enhance machine utilization, reduce operation time, and improve overall efficiency. With strategic partnerships with major OEMs and tier-one suppliers, GKN Aerospace required a robust system to manage and analyze machine data in real-time, allowing for timely interventions and quality improvements. The company also aimed to integrate this system with their existing ERP SAP to further streamline operations and achieve continuous improvement. Read More
About Customer	GKN Aerospace is one of the world's largest independent first-tier aerospace suppliers, providing complex, high-performance, high-value integrated metallic and composite assemblies for aero structures and engine products. Based in Newington, Connecticut, USA, the company has a reputation for investing in technological innovation to bring real and practical benefits to their customers, aircraft operators, and passengers. GKN Aerospace's Engine Systems division, which accounted for 50% of sales in 2013, operates in a low-volume, high-mix environment and has close strategic partnerships with major OEMs and tier-one suppliers such as General Electric, Pratt & Whitney, Rolls-Royce, Snecma, and MTU. Read More
Solution	GKN Aerospace implemented FORCAM’s Advanced Shop Floor Management Technology, FORCAM FORCE, to improve manufacturing productivity. This technology allows the company to see production data in real-time, analyze machine states, and make timely interventions for quality improvements. The system provides a visual display on the plant floor, showing status information and enabling operators to signal line status based on color codes. This real-time visibility helps in increasing throughput efficiency and overall equipment effectiveness (OEE). The technology also supports continuous improvement activities by providing instant feedback on performance changes. In Phase 2, GKN Aerospace plans to integrate FORCAM FORCE with their ERP SAP to further enhance operational efficiency. Read More Log in to view content
Contents

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)

Analytics & Modeling - Predictive Analytics

Application Infrastructure & Middleware - Data Visualization

Applicable Industries

Aerospace

Applicable Functions

Process Manufacturing

Maintenance

Quality Assurance

Use Cases

Machine Condition Monitoring

Predictive Maintenance

Energy Management System

Process Control & Optimization

Real-Time Location System (RTLS)

Services

System Integration

Data Science Services

Training

Challenge

GKN Aerospace, a leading aerospace supplier, faced the challenge of improving manufacturing productivity in a low-volume, high-mix environment. The company needed a solution to enhance machine utilization, reduce operation time, and improve overall efficiency. With strategic partnerships with major OEMs and tier-one suppliers, GKN Aerospace required a robust system to manage and analyze machine data in real-time, allowing for timely interventions and quality improvements. The company also aimed to integrate this system with their existing ERP SAP to further streamline operations and achieve continuous improvement.

About Customer

GKN Aerospace is one of the world's largest independent first-tier aerospace suppliers, providing complex, high-performance, high-value integrated metallic and composite assemblies for aero structures and engine products. Based in Newington, Connecticut, USA, the company has a reputation for investing in technological innovation to bring real and practical benefits to their customers, aircraft operators, and passengers. GKN Aerospace's Engine Systems division, which accounted for 50% of sales in 2013, operates in a low-volume, high-mix environment and has close strategic partnerships with major OEMs and tier-one suppliers such as General Electric, Pratt & Whitney, Rolls-Royce, Snecma, and MTU.

Solution

GKN Aerospace implemented FORCAM’s Advanced Shop Floor Management Technology, FORCAM FORCE, to improve manufacturing productivity. This technology allows the company to see production data in real-time, analyze machine states, and make timely interventions for quality improvements. The system provides a visual display on the plant floor, showing status information and enabling operators to signal line status based on color codes. This real-time visibility helps in increasing throughput efficiency and overall equipment effectiveness (OEE). The technology also supports continuous improvement activities by providing instant feedback on performance changes. In Phase 2, GKN Aerospace plans to integrate FORCAM FORCE with their ERP SAP to further enhance operational efficiency.

Impact #1	GKN Aerospace achieved a 20% reduction in operation time, leading to increased direct labor efficiency and on-time delivery.
Impact #2	The implementation of FORCAM FORCE allowed for better machine utilization and cost reduction.
Impact #3	The visual lean manufacturing environment provided by FORCAM FORCE enabled operators to signal line status and react promptly to issues, improving overall equipment efficiency (OEE).

Impact #1

GKN Aerospace achieved a 20% reduction in operation time, leading to increased direct labor efficiency and on-time delivery.

Impact #2

The implementation of FORCAM FORCE allowed for better machine utilization and cost reduction.

Impact #3

The visual lean manufacturing environment provided by FORCAM FORCE enabled operators to signal line status and react promptly to issues, improving overall equipment efficiency (OEE).

Benefit #1	20% reduction in operation time
Benefit #2	Lead time reduced from 50 days to 34 days

Benefit #1

20% reduction in operation time

Benefit #2

Lead time reduced from 50 days to 34 days

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Overview

GKN Aerospace Achieves 20% Reduction in Operation Time with FORCAM FORCE

Operational Impact

Quantitative Benefit