Lean Manufacturing Blog

Ventra to integrate eFlex Software in its Sandusky plant for complete traceability of its automotive lighting production

Created: 27 March 2017


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Visit eFlex Systems at the Automate Show 2017, Booth #2419

Created: 25 March 2017

Visit eFlex Systems at the Automate Show April 3-6, 2017 at the McCormick Place, Chicago, IL.   Check out our MES Solutions for manufacturing including eFlex Vision Image Management Software.  Live demos available for hands on experience of our software capabilities.  

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Nissan Awards eFlex Systems to Implement Assembly Software for Another Decherd Engine Line

Created: 16 February 2017


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Navistar to integrate eFlex System's Flexible Assembly Technology into its Springfield Plant for the production of GM vans

Created: 12 December 2016

News Release: Rochester Hills, Mi - December 9, 2016  

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GM Refurbishes 4-Cylinder Engine Plant to a V8 Line in a Cost Effective, Timely Manner Using eFlex Software

Created: 14 November 2016

Rochester Hills, MI - November 14, 2016:   

As noted in the Detroit News on February 19, 2016, General Motors invested $148 million into its Spring Hill Engine Manufacturing Plant in Tennessee to repurpose flexible machining and assembly equipment to meet market demand.   While the facility has been producing 4-cylinder engines, they will now be updating features that will allow them to quickly adapt manufacturing lines to start producing the Small Block 6.2L V8 engines for the ever growing truck and SUV market segments.  According to Arvin Jones, GM North America Manufacturing Manager,  "The flexibility of Spring Hill's engine machining and assembly equipment is allowing GM to respond deftly when additional engine variant capacity is needed."

The assembly line was originally built for the production of 4-cylinder engines with eFlex Systems Flexible Assembly Configuration Software (FACS).  This software provides process and control standardization within a modular plug and play system. "As a result of this flexible architecture, GM was able to repurpose the assembly line from a 4-cylinder to a V8 engine line in record time and at cost savings." said Dan McKiernan, president of eFlex Systems.  Typically, traditional architecture assembly lines would be cost prohibitive to repurpose a line in this matter.  FACS allows a line to be reconfigured quickly, in this case less than 10 months, without having to buy a new one.  Because of the standardization, GM was able to just buy new tooling for most or part of the project and rebalance the line to produce V8 engines.  

The line also included eFlex Vision Inspection Software which is a central image storage product that provides an integrated environment for managing and retrieving process images from vision inspection systems.  This system allows manufactures to improve quality by identifying problems as soon as they occur, and prevents defective parts from reaching the customer.  If a quality problem occurs or a warranty claim is made, engineers can quickly find the information they need to identify the root cause of the problem, or provide evidence to prove if the plant is not at fault.  

Our products used on the line included eFlex Assembly (FACS), eFlex Process Improvement Tool (PIT) as well as eFlex Vision (Vision Inspection Image Management).  Per Dan McKiernan, President at eFlex, "The implementation of eFlex Software in the Spring Hill plant ensured the right balance of technology, flexibility and lean manufacturing principles to meet changing market demand while maintaining the highest quality." 



Source: Detroit News - GM Photo


To view more about GM's investment in the Spring Hills plant click on the links from the Detroit News or GM Corporate News Room.  

About eFlex Systems

eFlex Systems is a recognized industry leader in the design and implementation of advanced technology and world-class assembly optimization solutions for the manufacturing and information technology markets. We can help you achieve the right balance of technology and lean manufacturing principles to meet changing market demands. Serving a global customer base, we continue to expand our production assembly optimization expertise. We rely on our reputation as a world class manufacturing software company and manufacturing consulting firm to both attract new customers and preserve our relationship with existing clients. Our team includes a diverse group of engineers from manufacturing, software and consulting disciplines.

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eFlex Systems Releases Job Element Light (JEL)

Created: 12 October 2016


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eFlex Systems Releases Job Element Monitor (JEM)

Created: 15 August 2016

New Software Release:  eFlex has released our electronic job instructions software which will work in conjunction with eFlex Assembly.  Instructions can be shown for the station or each task.  Additionally, as tasks are enabled and completed, the JEM software will automatically show the current task status, time, instruction image and instruction text.

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Join Us in Booth #348 at The Assembly Show 2016 for a Demo of our Traceability Solution

Created: 19 September 2015

Come and visit eFlex Systems at booth #348 at The Assembly Show 2016 to find out how eFlex Track & Trace, our Traceability &  Quality Management Software, can help with part traceability and quality management.

Visit our booth to see how our software works and the capabilities we can bring to your manufacturing organization. A sample screenshot of this software is below:

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Nissan Incorporates eFlex Assembly Technology Suite In State-of-the-Art Infiniti Decherd Powertrain Plant

Created: 09 March 2015

Nissan recently opened their Infiniti Decherd Powertrain Plant, embracing the eFlex Assembly Lean Leveraging Technology suite. This highly flexible suite provides the four-cylinder assembly line the ability to easily rebalance, reconfigure and report on current status and the impact of continuous improvement efforts, for both the planned Mercedes-Benz and Infinti engine production.

Photo source: Blake Farmer / WPL

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eFlex Assembly Featured in Assembly Magazine Article: Decentralized Control Lends Flexibility to GM Plant

Created: 03 February 2015

Decentralized Control Lends Flexibility to GM Plant

Below are the first few paragraphs from this article, with links at the end to read the full article. Please Note: The article discusses how eFlex Assembly (they reference it as FACS) was used by GM to make their assembly system flexible.

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Assembly Line Comparison Study:

Flexible Assembly Line vs Highly Automated Fixed Tooling

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Your assembly line’s output must reflect market demand, adapt in a fraction of the time, and maintain quality. Download this case to see a comparison between two assembly lines: one highly fixed and the other flexible.


Inflexible Assembly Line Case Study:

"Market Change Results in Lost Sales Due to 'Inflexible' Fixed Tooling Assembly Systems"

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Read this case study to learn how a global manufacturer with an “inflexible” assembly lines was NOT prepared to handle an overnight shift in demand, resulting in lost sales. To fix this issue, this major automotive manufacturer implemented eFlex Assembly on their global powertrain assembly lines to achieve great results!


Case Study:

eFlex Vision Processes 200,000 Images Per Day on a High Volume Transmission Assembly Line

Download this CaseStudy

A large automotive manufacturer uses eFlex Vision to process over 200,000 process images per day, at roughly 200 images per minute. Learn how eFlex Vision increases their image accessibility and reliability, reduces complexity and maintenance costs, decreases response time to camera issues, provides camera audit trail tracking and much more.