Industry Challenges
The Automotive Industry is a globally competitive environment that quickly separates the winners and losers. The winners are characterized by a willingness to continually improve and drive out waste and cost.
Phoenix Systems has worked very closely with the Automotive Industry for over 20 years and has documented 
success in a number of major projects. Our list of clients includes Chrysler, Ford, GM, Toyota, and many Tier One and Two suppliers. We have provided expertise and extensive systems support in throughput improvement, formability, run-to-run, logistics, total productive maintenance, and leadership and team development. The key difference that defines Phoenix is knowing how to make improvements last.
Most organizations know what to do and are familiar with most of the common improvement methods including lean, six sigma, process control, etc. The main problem is usually how to do them effectively. Phoenix has a 20 year history of implementing systems solutions in manufacturing operations. That experience is coupled with a strategy to live through the changes with our clients, and work shoulder to shoulder with them through the implementation.
Support we offer
identifies and quantifies improvement opportunities in uptime and cycle time. Improvements to tools, equipment, and work practices are prioritized and implemented in a systematic manner with the goal of maximizing production capability. Elements and components include Leadership alignment and training, the Pioneer and Advanced Throughput Improvement Systems, data collection, analysis, validation and documentation, Action Management System, problem solving methodology, standard work, recipe/set-up sub-system, process optimization, and cycle time improvement.
will fix the dies, keep them fixed, launch new product and optimize material usage. The Formability System includes 3 sub-systems: Formability Analysis, The Reference Panel System, and Tool & Die Maintenance Operating System.
o Formability Analysis: conduct high quality strain analysis and panel analysis to determine stability, robustness and die improvement opportunities. Lead die improvement planning with die shop personnel, and create status and reference panels for use on the floor.
o The Reference Panel System: at the press lines for use in the OK panel process, to ensure a stable recipe, for use in efficient problem resolution, and for maintenance.
o Tool & Die Maintenance Operating System: improve the effectiveness for prioritizing die work, scheduling, assigning, implementing, and then validating the benefits associated with the die work. Documentation and data analysis are key elements of the T&D MOS that drive lower costs, improved performance, and increased utilization.
emphasizing precision, set-up consistency, and part integrity, the Run-to-Run System ensures optimal changeover from running one part to running a different part. Regardless of equipment or manpower constraints, this focus on precision and the man/machine interface provides lasting improvement that result in minimal time for changeover. This unique approach is coupled with a broad expertise in technical solutions for the most difficult challenges.
Quality Systems – assessment, design, implementation and improvement of an organization’s quality system. Our expertise includes the following ISO standards: ISO 9001, ISO/TS 16949 (including Core Tools), ISO 14001, ISO 17025, ISO 13485, and AS 9100. Phoenix’s primary goal is to help an organization not only meet the ISO requirements, but to improve their business performance and enhance customer relationships through reliable and consistent quality performance. Phoenix also provides quality system training and comprehensive auditing services.
ensuring minimal inventory, optimal throughput flexibility, and disruption-free flow of material. The elements of the Logistics System include planning, tracking, and data analysis, Facility Layout, Inventory Control, Material Flow, Scheduling, and equipment installation expertise. The primary strategy is to reengineer present facilities and processes for implementing a Lean manufacturing system including Kanban/pull systems. These systems include part presentation to production process, rack and container design and optimization, work-in-process (WIP) storage and movement, finished product storage and movement.
assures optimal equipment condition that produces quality products at the maximum rate and minimum cost. A Total Productive Maintenance (TPM) System is achieved when the chief metric becomes Operational Equipment Effectiveness (OEE) that creates a cooperative effort between Production, Quality and Maintenance personnel in the pursuit of continuous improvement.
o Leadership Development – creates self-sustaining Leaders capable of ongoing management of change and driving continuous performance improvement. These individual Leaders will be developed as a result of the methods and processes used to effectively implement both improvement initiatives (Throughput Improvement System, TPM, etc.) and foundation systems (Action Management and Team Environment).
o Team Environment –ensuring that teams are developed at all levels of the organization including production, services, and support functions with roles that are clearly defined, measured, and audited.
o Workplace Organization creates an effective work cell layout including readily available information, job aids, and storage of machines, tools, and material. The best layout enhances performance and ergonomics and could be different from area to area. The best design technique utilizes affected personnel to ensure a robust layout.
Workplace Optimization integrates man, machine, material, product demand/mix, and methods across the entire organization. Workplace Optimization maximizes the entire organization’s performance and fosters continuous improvement. It does not permit sub-optimizing overall performance to improve a single work cell’s organization.
success in a number of major projects. Our list of clients includes Chrysler, Ford, GM, Toyota, and many Tier One and Two suppliers. We have provided expertise and extensive systems support in throughput improvement, formability, run-to-run, logistics, total productive maintenance, and leadership and team development. The key difference that defines Phoenix is knowing how to make improvements last.
