Production Control Tower at a $4B Manufacturing Company

‍Overview

Lack of end-to-end visibility, collaborative tools, and anomaly notifications led to increased inventory, low-performing schedule adherence, and significant disruptions to the production lines in the manufacturing industry.

Customer Challenges

Lack of Visibility:

Issues with inventory and material availability and poor visibility to inbound shipments.

Ineffective Collaboration Tools:

Insufficient tools among schedulers, material planners, and line coordinators.

Disconnected Systems:

Disparate data sources leading to production disruptions.

Production Disruptions:

Significant disruptions to production lines, schedule attainment issues, and loss of manpower potential.

Excess Inventory:

Surplus inventory and dead stock due to inefficiencies.

Scope of Implementation

• 540,000 Parts

• 1,700 Active Suppliers

• 17 Assembly Lines

• 6 BOM Tiers

• 500+ Users

• 150 Machines/Day

• 23 Data Systems

Solution

Customer implemented TADA’s solution to address its production control challenges and achieve its strategic goals. TADA’s AI-Enabled Digital Twin technology provided the following benefits:

Digital Twin:

Created a digital twin of the customer’s business processes and systems.

Schedule Attainment:

Optimized production plans based on available products and parts, managed capacity, and improved daily KPIs and collaboration cadence.

Real-Time Visibility:

Enabled real-time supply chain visibility for internal operations and inbound shipments.

Storage Density:

Improved storage density and reduced stranded or lost material.

Persona-Based Portals:

Enabled six persona-based portals for efficient management of manufacturing disruptions.

Results

Time Savings:

• Earned Hours Gain: Increased from 854 hours to 1,669 hours

• Planning Effort Reduction: 60% reduction.

Increased Efficiency:

• Team Efficiency Gain: $2.4 Million Reduction

• Factory Productivity Gain: $11.7M (in 3 months)

Enhanced Collaboration:

• Improved schedule attainment: From 45% to 91%.

• Incremental revenue potential: $92.1M in Improvements

Inventory Reduction:

• Inventory: Reduced from $100M to $77M

• Total Inventory Improvement: $23M

‍Conclusion

TADA’s Production Control Tower optimized the orchestration of production operations to be, transforming the way manufacturing processes are managed and executed. TADA addressed critical challenges while also enhancing collaboration and streamlining workflows. This strategic implementation has empowered the customer to make informed, data-driven decisions, driving continuous improvement and operational agility.