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Advanced Sequencer

Advanced Sequencer

Use a simple dashboard to view and edit the daily sequence of vehicles across multiple areas and lines to increase production throughput

Unit Sequence Visualization

The Advanced Sequencer provides a quick view of labor demands for each station and each unit during each takt cycle throughout the day for high model-option variation environments. Production supervisors often struggle with daily order sequencing when part availability, quality, or production resource issues occur. In addition, when units with many options are in production, they create labor challenges due to long cycle times. The Sequencer's charts make it easy to identify when and where potential issues could occur and where floating operators should be assigned. 

Station Utilization Chart
This chart provides a clear indication of which units will cause potential issues at which stations and at which times of day. The chart can display the graphical view of each unit's cycle time and display its takt time utilization. A user can view the chart by time of day or view one unit at a time. 

The Time of Day chart can display the work content in relation to a takt time line for multiple units across multiple stations for multiple takt cycles, with the units in the current takt cycle shown in red, as shown in the image at the top of this page.

The By Unit chart can display the work content in relation to a takt time line for a single unit in all of the stations that it will pass through. 

Takt Overage Alerts

The charts highlight the unit/station/time of day combinations for which issues could arise due to excessive work content. Users can set percentage values to be used to determine warnings (shown in yellow) and for alarms (shown in red). For example, the users can specify that if work content between 95-105% percent of takt, a yellow warning will be displayed, and if the work content exceeds 105% of takt, a red alarm will be displayed. 


Takt Overage Alerts by Time of Day


Takt Overage Alerts by Unit

Manual and Automatic Sequencing

Predicting when and where additional labor is needed throughout the day is what the Advanced Sequencer does best.

Users can use the visual alerts to identify issues and, with a few clicks, re-sequence orders to avoid those issues. The spreadsheet view makes it easy to drag and drop or use a right click selection menu to move orders up and down the list. 

Users can also use the automatic sequencing tool to view a recommended order sequence based on preferences they've predefined. A preference can be set to:

  • Sequence orders to balance work content at a selected station or stations evenly throughout the day.
  • Sequence orders with less work content at a selected station or stations before those with more work content.
  • Sequence orders with more work content at a selected station or stations before those with less work content.

Detailed Reporting

  • The Daily Labor By Worker report charts the total work content at each station for a selected work day, visually displays the total time available in the work day, and calculates overall expected productivity for the unit's assembly. 

  • The Daily Labor for Orders by Worker report calculates and charts the time to be spent on each order by each selected worker in a given work day.

  • The Operator Labor By Day report calculates and charts the total time required for an operator to complete all units planned for his/her assigned station. This report is different from the Daily Labor By Worker graph because it reports only on a single operator and can report the work for that operator over multiple days.

  • The Average Labor by Worker report charts the average labor time for each operator in the time period selected. 

  • The Station Unit Details report can be generated for each operator and will list the orders the operator is scheduled to work on during a given day. The expected labor time and start time will be displayed and the operator can fill in actual production details as each order is worked on.

Does your team know the product configurations that cause the most disruptions but still is unable to consistently prevent them?
Sequencer Planner directly combines a scheduled set of order for a certain time period with the line balance and task assignments that will be in place. In a mixed model environment, this means that the exact work content for every operator for every unit is not only calculated but also graphically displayed and analyzed within seconds. The charts and warnings provided are critical to identifying where to send floaters in the short term to avoid line downtime, and how to adjust future scheduling rules to avoid running multiple units in a row that are known to fall over takt. 

Sequence Planner provides a unique yet simple analysis of the impact of a production schedule on the line:

  • Graphically view the work content by operator for one unit at a time or one takt cycle at a time.

  • Identify units ahead of time that will cause over-cycle situations. 

  • Right click to re-sequence units and fine tune the schedule for a particular day or week.

  • Compare and report daily labor details for alternative line balances and production schedules.

Proplanner provides a single system for engineers to create a plan for manufacturing. We suggest you review these solutions next:

PLM

PFEP updated driven by BOM/Engineering Change

MES

Work instructions synchronized with kit carts

APP

Activity part consumption signals parts requirements at a station

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