AceTech’s product group has created a prototype of a cutting-edge new product in a competitive category. It is critical that the manufacturing team bring the product to market in large volumes before the competition catches up. They set an accelerated timeline of 3 months to bring a new assembly line for the product online, as well as an additional month to work out the kinks and scale up production volume. Ava is leading the effort.
Ava and her team start to define the production process in a fragmented way across a number of tools including PLC programs for low level logic, Word documents for operator instructions, Excel sheets for machine settings, and third party tools for production flow.
Pashi allows you to define and manage your entire production process in a single, unified interface.
Ava is able to construct a unified Pashi Program that defines the logic and operation of the line. The Pashi Program contains all of the machine-level configuration, stage-level logic, HMI and other human interface screen definitions, and the product flow control logic for the entire production process end-to-end.
A system integrator works with the in-house engineering team to build and program the line but since the process definition is spread across dozens of documents and tools, progress is slow. The integrator is having trouble recieving all of the information and input they need from the many different teams on AceTech working on this production process.
Pashi lets manufacturers and their integrators design process logic, add devices and specify parameters collaboratively.
AceTech and their system integrators quickly get on the same page collaborating on the Pashi Program. As the integrators builds hardware on their facility, the Pashi deployment team works with them and with Ava’s production engineers to iteratively interface each device with Pashi. They are then each tested as part of the mostly-complete Pashi program for the line.
Some of the machines have arrived on the system integrator's factory floor but since the process specifications are unclear, Ava works with the integrator to ensure AceTech and the integrator get on the same page.
The system integrator delivers the completed line to AceTech's factory floor.
Specialized HMIs for QA stages and other data input interface devices arrive on the sytem integrator's factory floor. The system integrator brings in the required programming experts to configure them.
Pashi lets you create dynamic, customizable human interfaces including QA checksheets, operator instructions, and rich data input interfaces, using a blazing fast visual UI integrated into Pashi's production flow editor. These interfaces can be deployed in real-time to network-connected interface devices like tablets, TVs, smartphones or line displays within a production facility.
The Pashi deployment team works with AceTech’s in-house engineering and maintenance teams to ensure that the hardware integrations work as expected and that the program that AceTech production engineers have built runs end-to-end.
While the system integrator's programmers configure the SCADA system for data extraction, Ava is informed of a design change from the product group. Though it is a parameter change, a lot of logic needs editing so Ava brings in PLC programmers from AceTech to supplement the integrator's team.
Pashi lets production engineers change parameters quickly using the visual interface while also ensuring safety by allowing reversion to the previous parameters across the line with a single click.
Ava is notified of a design change from the product group. Since most of the changes involve altering some parameters, Ava is able to make them herself in just a few hours using Pashi.
The integrator finally delivers all of the hardware to AceTech's factory floor. Ava's team starts bringing it online end-to-end and begins test runs but while all the PLC programs are complete, they are bug-ridden and difficult to fix. Her team sets about prioritizing and allocating programmers to fix issues.
Pashi allows you to monitor the execution of process logic and all variable values live when the line is running, enabling fast and effective debugging.
While observing the test runs, the arm assembly stage torque wrench is not operating correctly. Ava notices that the conditional if statement deactivating the gun is not lighting up. This causes the wrench to misbuild the product.
The most severe issue Ava faces is the broken item forwarding flow logic. Ava decides to temporarily patch this by using manual OK buttons at each stage. This introduces a new problem for Ava: some SKUs of the product do not go through every single stage, requiring modifications to the PLC logic at each stage based on the variant being produced. Meanwhile, the SCADA system no longer works because of changes to the PLC logic and stage configuration.
Pashi lets you view real-time production metrics and create KPIs customized to your industry and process.
After validation, okay to buy, and signoffs, the assembly line is now operating end-to-end and the first units are ready to ship, but cycle times are both too high and too variable resulting in unpredictable and low throughput. Ava uses Pashi’s built-in analytics tool to quickly do a bottleneck analysis and suggests changes to the line design to reduce and normalize the cycle time.
An accidental wipe of the PLC program on several of the stages results in them having to be rewritten from scratch since the latest versions of those programs could not be located on the computer with the PLC programming software.
Pashi uses comprehensive version control to track changes made to process flow and parameter logic. This allows for testing of process changes and optimizations with the safety of one-click reversion to the previous stable configuration.
Ava decides to test new logic to solve the throughput issue and creates a test version. But this logic results in misbuilds and she reverts back to the older stable version and starts rethinking the problem.
Ava’s PLC programmers finish rewriting the logic and are now back to where the implementation was left off: validating the machines. During the validation runs, Ava notices the torque wrench in the Arm Assembly is behaving abnormally. After thoroughly testing the torque wrench hardware and finding no fault, Ava asks the system integrator to bring in their PLC programmer to solve the issue.
The production line is now capable of running at full capacity 19 days ahead of schedule. The QA team takes this opportunity to extensively test the units and spot a critical error in the product design and report it to the product group, which begins to work on a fix.
The programmer comes in and reviews the ladder logic. He tells Ava that it was was a typo and manages to fix it relatively quickly.
Pashi allows for a customized and complex production routing including splitting and merging production lines, non-linear production flow and programmable flow logic.
After working on the bottleneck for a while, Ava settles on the solution of splitting the line with two parallel welding stages. She is able to program this in Pashi just a few minutes after setting up the physical stages.
With the typo issues resolved, Ava's team gets back to finishing machine validation.
Pashi lets you quickly deploy and connect temporary stages to deal with short term issues and allows for quick disengagement of those stages when the issues are resolved.
The product team’s design change arrives and Ava is able to integrate it into the production line in under a day, adding an additional temporary quality check stage in Pashi using a generic Android tablet in order to ensure the design change has fixed the problem.
The project is now officially behind schedule. While Ava's team performs validations, new issues crop up, including a welding design flaw, forcing her team to spend more time editing logic, re-validating and testing. Ava rushes to start implementing an MES to satisfy new traceability requirements imposed as a result of these issues.
Pashi allows you to build and customize production dashboards like OEE and cycle time variability.
The AceTech produciton line is running at full volume with high OEE. Since AceTech's product is the first to market in its category, it sells in massive quantities and establishes brand equity as the market leader.
AceTech launches but struggles with scaling up production and is running at one-third of the peak volume. In an attempt to increase production throughput, Ava attempts to perform a bottleneck analysis, but is frustrated by the SCADA system still not having been updated to comport with the latest production logic, and has to extract data from each of the stages individually. Data extracted from each stage turns out to be incomplete and Ava commissions software engineers to write custom data acquisition code to solve this problem.
Pashi allows you to quickly integrate new SKUs with different process routing and logic into a production line.
The product group and Ava collaborate to introduce a new ergonomic design variant based on customer feedback. It only takes a few days to integrate this new SKU into the production process using Pashi since the new design only require one different part and minor changes to assembly and flow logic.
After a great deal of work, the PLC logic has once again been rewritten, the MES system has been integrated with the SCADA system and the PLCs, and the entire line appears to run end-to-end. Unfortunately, Ava detects that incompatibility between the new MES system and the custom data acquisition code being used means that incorrect values are appearing on genealogy logs. She decides to migrate data acquisition into the MES. Meanwhile, BaseTech, a major competitor, has launched a similar product which captures market share on the back of pent-up demand that AceTech’s minimal production volume cannot cover.
Pashi automatically creates a timestamped traceability log of your product as it interacts with every stage and device.
AceTech's rival BaseTech has launched its own product but is seen as a lower quality copy and it doesn't make a dent in AceTech's market share. Ava's team launches the new ergonomic version of the product.
The production line is finally running at the required throughput. Unfortunately, customer feedback suggests that users prefer the ergonomic shape of BaseTech’s device to AceTech’s. The product group rushes out a new external body design that they send Ava. Until this new design can be integrated and scaled up, the line continues to run at one-third capacity since the demand for AceTech’s product has collapsed.
AceTech prepares to launch a second line to meet rising customer demand and become the majority player in the segment. BaseTech falls to a far second place.
Ava’s line is now capable of producing the new ergonomic shape customers wanted but with BaseTech capturing most of the market share, AceTech has no choice but to sell this new version at 60% of the price BaseTech's product sells at and become cut-rate players in the market.
The production line continues to run at full capacity. The second production line for this product is going live today.