Assembly Line Rollout
Assembly Line Rollout — From Downtime to Peak Stability
A large assembly plant struggled with frequent stoppages and unstable output across shifts. Unplanned downtime was eating into production targets and inflating costs.
Downtime Δ-18%OEE92.1%Payback< 3.7 mo
Challenge
- Frequent stoppages across shifts.
- Unplanned downtime cut into targets and inflated costs.
- Inconsistent reporting and changeover discipline.
Solution
- Inline quality checks to monitor product metrics continuously.
- Automated alerts tied to downtime triggers.
- Standardized shift reports and changeover playbooks.
Results
Downtime reduced
-18%
OEE above
92.1%
ROI in
< 3.7 mo
Toolkit Provided
Standard alert playbooks
Faster operator response with predefined actions for each common fault.
Shift report templates
Transparent accountability across teams with consistent metrics.
Changeover best practices
Smoother handovers and fewer disruptions at shift boundaries.