Assembly Process Planning
Integrated modules for Time Estimation, Line Balancing, Ergonomics, and Work Instructions designed specifically for assembled products guarantees the quickest results with the least amount of customization and training.
Have you struggled to create accurate mixed-model line balance in Excel that demonstrate and help you evaluate the impact of all models and options, instead of just the top 2 or 3?
Proplanner provides teams with advanced analysis and balance capabilities, leading to results such as a 34% improvement in utilization.
Do you spend hours collecting data and creating status reports for management that you know someone else has already created before?
Proplanner makes it easy to share data and have one common definition of the assembly process, so you can gather and present the information you need within minutes.
Do you get frustrated having to update separate time study, line balancing, work instructions, and other process-related documents or systems because of a single product design change?
Instead of 4 people updating 4 documents or more, 1 person can make 1 change to update all documents at once.
A centralized master location for editing and maintaining all process planning data
Improve process planning with 3D visualization and manipulation
A centralized location for all time study data with a tight link to the process routing, work instructions, and line balance
Visualize and quantify task requirements for all models and options to achieve a better balance of work across all operators
Auto-generate standardized, up-to-date visual work instructions for every model and option configuration in seconds
Analyze the impact on health and human factors of job assignments
Maintain accurate documentation to predict and prevent quality issues
Visualize and analyze walk-path diagrams directly within AutoCAD to determine operator walk times, value-added work, travel distances, ergonomic impact, and more
Have you spent too many hours, even days, inputting part routing information into your ERP system?
You can maintain a single routing per assembly line and let Proplanner send ERP the data it needs in the format it needs for every unit you make. For one manufacturer, this meant $2 million in savings and 4 weeks of extra production during one model launch.
Do you fail audits because what is happening on your line is not synchronized with your work instruction, PFMEA, and Control Plan documents?
PFMEAs, Control Plans, and Work Instructions are all tied to the line balance, allowing for a single process database to update all documentation.
Do you struggle to make sure operators have the correct parts and tools after a re-balance?
A list of tasks, tools, and parts that must move can be automatically generated to help physically transform the line in preparation for a rate change.
Engineers working in their own spreadsheets create losses throughout the organization, including wasted engineering effort and sub-optimal process plans. Multiple definitions of the process need to be manually reconciled at a later date. Proplanner solves this issue by:
Centralized location for all process planning data
Library of activities which can be reused throughout the plant
Videos linked to activities to establish process times, ergonomics, waste analysis, and line balancing improvements
Single master routing which can be maintained for the entire assembly line
List of tasks, tools, and parts that must move due to a line re-balance
eBOMs are imported automatically and can identify impacted processes
Line balance is updated automatically when new time standards are generated
PFMEA and Control Plans are tied to the same processes defined in the work instructions and line balance
Routing updates are configured and sent to ERP automatically
Proplanner provides a single system for engineers to create a plan for manufacturing. We suggest you review these solutions next:
Line balance scenarios can be merged with order details to perform advanced scheduling and operator allocation
New work instructions are generated automatically when new line balances are developed
Parts can be mapped directly from the BOM to tasks in the routing
Parts mapped to tasks can update logistics planning (PFEP)