Foxconn - Introducing Smart Factory Management System

Solutions

Foxconn uses MicroStrategy to achieve smart factory management. They are focused on the following 4 directions:


  1. Focus on the important core aspect of automated production equipment management
  2. The key to guaranteeing production capability and quality is to precisely grasping the status of every machine. MicroStrategy can acquire real time output, material usage, and other information of the machines through a top down approach starting from the overall status. Users can check the output amount and variations of the equipment on the same product line. The main observed indices are: machine output target achieved rate, order closure, first and last product quality analysis, and machine output comparison.


  3. Product line real time inquiry and repair platform
  4. The line, work segment, work station, work positions are marked with different shapes and colors. The line manager can know if production capacity and completion rates are reaching targets every 15 minutes. They can track order progress, work status related information, and provide the "fast repair" function; effectively increasing equipment utilization rate. It also lowers the effect of hardware malfunction on production capacity. The main monitoring indices are: production capacity monitoring, completion rate monitoring, order completion, work status, and equipment utilization.


  5. Focus on core problem analysis of automated production
  6. Collect automated product line data and explore the different factors that cause production to not reach targets. The factors include the floor, machines, abnormal factors, and more. Cross analysis is used to focus on the key issue and confirm the correct action to correct the problem. The main observation indices are: output completion rate, factors affecting production capacity, factors affecting quality, ranking of factors affecting equipment, production performance ranking, and production process summary.


  7. Understand smart factory operations in one minute
  8. Quickly understand the real time status of each factory and product. Use the simple human machine interface of MicroStrategy to get visualized data, problem analysis, and inspect execution results. Formulate action plans or confirm important decisions according to real time information. The main observation indices are: machine KPI, production capacity achieved, overtime WIP, order tracking, shipping OQC, and equipment error analysis.



The picture below shows a smart factory operation page diagram. The picture comes from the iPASP platform.


Foxconn - introducing smart factory management system1

Foxconn - introducing smart factory management system2


Foxconn - introducing smart factory management system3


Achieved Effect

Effect comparison chart for before and after Foxconn introduced MicroStrategy:

Objective Before After Improvement
Repair procedure 3 hrs 30 mins Use one button repair to automatically call repair teams for onsite repairs and track repair progress online.
Information delivery Deliver information through hard copy sheets and reports The interactive board displays graphical information in real time, including production information, goals achieved, bottleneck stations... Display important index information in real time through the interactive board.
Monitoring frequency once a day once per 15~60 mins The key index changes from "after action evaluation" to "mid action control and incident prevention" to increase efficiency.
Error response once per 4 hrs once per 15 mins Increase the response speed and communication regarding problems to increase manageability and utilization rate.
Utilization rate 95.5% 98.5% Manage the usage life span of materials during production to estimate replacement times; helping with material preparation and calibration.
Periodic quality testing, lower re-production "One time completion rate" and "final completion rate"are worse. "One time completion rate" and "final completion rate" are better than before. Through first and last piece, blade replacement, daily equipment testing, and other maintenance processes, users can perform specific maintenance and calibrations according to the testing reports; improving one time completion rate and final completion rate.

※ The content of this article was based on information provided by the manufacturer.



Relevant Cases:

  1. IoT Manufacturing Machine Case- KNIME Error Detection and Prediction System
  2. LED Packaging Manufacturing Case- Introducing the iPASP System
  3. Plastic Mold Industry Case- Introducing the iPASP System
  4. Semi-conductor IC Testing Case- Introducing the iPASP System
  5. Precision Technology Industry Case- Introducing the iPASP System
  6. Certain Manufacturer- MicroStrategy Sales Analysis Management Platform
  7. POSCO Korea Steel Plant- IBM SPSS Modeler Quality Prediction and Control System


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