Digitizing a manufacturing process can be a precarious task. Yet, our software, GE Digital, which enables Industry Internet of Things (IIoT), has successfully digitized its operations across the Grove City Remanufacturing Facility. Our software helps this unit in managing and exchanging data, and it centralizes various pipelines of data from all workstations within the manufacturing facility which allows easier access of information regarding the downtime, shift rollouts, and units being produced.
This facility, located in the Groove City, is widely spread across a land of 240,000 Square Feet. All the freight locomotives out of the 26,000 that operate across the United States are sent to this unit for repairs. In most cases, a locomotive engine doesn’t require a repair for ten long years. But in the hour of needs, with respect to repairs, this enormous remanufacturing unit comes to the rescue. In the pre-digitized period (before 2013), the facility faced timeline issues due to the manual nature of operations within different operational units. In 2013, the entire process was digitized. Now, all the mental parts undergoing processing are serialized and heavy tools have become safer and easier to operate.
Now, over 1200 engines are rebuilt every passing year. Different sub-units are sensor integrated that further explain the performance of the engines that have entered the facility for repair and also clearly state the revamp required on them. The efficient digital performance on these American freight locomotive engines is self-explanatory as they are sent back within ten days in an excellent working condition.
The centralization of the processes through this software now allows 96 different stations to report out in real time, up-to-date information of all sub-units can be accessed from anywhere and all the supervisors of different divisions can oversee the run-time of multiple jobs and employees operating in different shifts. From our technological standpoint, the futuristic vision behind employing this software is already reaping rewards. The Groove City site is already operating paperless and the data consolidation which took five days earlier is now real-time. The massive reduction in unplanned downtime (20%) has been a key payback as well. The organizations still striving for paced manufacturing might have an apt solution for their struggles.
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