The average annual production of the plant is 324K Engines, which are supplied to the vehicle assembly plants of Valencia, Hermosillo, Saarlouis, and Louisville. In addition to shipping engines, it ships mechanized engine components like a Cylinder Block, Cylinder Head, Crankshaft, and Camshaft (600K sets / year) to send the Cleveland engine assembly plant at USA.
To manage the variant’s manufacturing complexity, the plant is working with weekly batches managed manually using the experience of MPL and production personnel. Currently, the assembly line is manufacturing 25 different derivatives depending on the vehicle where it will be installed. Apart from the 4 engine components manufactured in Valencia, each of these derivatives needs different components such as the engine crankcase, petrol pump, oil pump, and clutch, and this manufacturing complexity is managed manually using the experience of the MP&L and production personnel and static restrictions of line production. We need a system that feeds real-time data and updates the restrictions of the line production and advice what is the best batch and mix of products.