Industries · Assembly & General Manufacturing
OEE for Assembly & General Manufacturing — Protect Flow Through Every Station
Multi-station lines, frequent model changeovers, operator-paced work. ACI helps European assemblers see every minute lost from first station to final pack and cut waste on manual, semi-automated and fully automated lines, using Vorne XL and OEE IntelliSuite.
Why this industry is different
The Losses That Cost Assembly Lines the Most
Assembly lines don’t fail like continuous-process lines. The costliest losses are model and SKU changeovers, stations starving or blocking each other, and micro-stops that never make it into a shift report. This is where XL and OEE IntelliSuite pay back fastest.
Model & SKU Switches
Frequent model and variant changes eat into throughput. XL captures every changeover automatically, splits planned from unplanned, and shows where the SMED target is being missed.
Stations Starving & Blocking
When one station runs slow, the whole line waits on it. Treating starving and blocking as measured, station-level events surfaces the imbalance nobody’s tracking today.
Jams & Short Stops
Sub-minute stops on feeders, fixtures and conveyors are invisible in daily averages but massive over a shift. Real-time run/stop per station means operators react during the shift, not after.
Rework & Reject Loops
Reject and rework patterns tied to shifts, reason codes and SKUs not buried in end-of-month totals. Root cause becomes obvious; rework time drops.
Replenishment Delays
Empty bins and late kits stall stations without ever showing up as a proper downtime reason. XL captures them as their own state so materials teams can react inside the shift.
The Planned-vs-Unplanned Blur
Every stop, every downtime reason, every operator interaction time-stamped and queryable so root-cause reviews and audits stop being fire drills.
For every kind of assembly line
Manual, Semi-Automated, Automated & Mixed-Model Lines
The specifics differ, but the discipline is the same. XL sees what your line is really doing; OEE IntelliSuite turns it into decisions your team can act on today.
Manual Assembly Cells
- Operator-paced cycle times
- Station-to-station balance
- Skill and training gaps
- Model-mix changeovers
Semi-Automated Lines
- Automated station cycle vs rated
- Operator-machine handoffs
- Jam and micro-stop reasons
- Manual-station bottlenecks
Fully Automated Lines
- Speed vs rated by station
- Fault and fault-reason capture
- Changeover and recipe loads
- Unplanned vs planned downtime
Multi-Product & Mixed-Model Lines
- SKU and variant changeovers
- Line balancing across models
- Short-run setup time
- Cross-model quality trends
Trusted across the sector
Assemblers Running the ACI Stack
A representative selection from manual assembly cells to fully automated, multi-station lines. Drop your customer logos into these slots.
Want to be on this wall? Start with a Performance Audit or a 45-day free trial on one line.
What ACI delivers
A Stack Built for Assembly-Line Reality
Not just a scoreboard. A measurement layer, an operator workflow, an analytics layer, and the hands-on coaching to make sure your team uses it every shift.
- Vorne XL device on the line automatic run/stop, speed vs rated, downtime reasons, and station-level changeover detection. Live on a floor-facing scoreboard.
- OEE IntelliSuite analytics jobs and schedules, operator context, alerts by email/SMS/Teams, and 40+ analytics visualisations tuned for discrete, station-based lines.
- Integration with your systems ERP (SAP, Oracle), MES, SQL, MQTT/OPC and Power BI. Master data flows in; production truth flows out.
- Hands-on ACI coaching on-site setup and training in Dutch, French or English, plus follow-up so the daily routine holds through every model changeover.
What a good six months looks like
Measured Improvements Assembly Lines Typically See
OEE lift when one focus metric is set per month
OEE gain in ten weeks on a mixed-model line
Annual production recovered in three weeks
Changeover root causes found in minutes, not shifts
Documented XL customer results across assembly and general manufacturing lines. Actual results depend on your starting point, lines and follow-through.
Questions
Assembly OEE Common Questions
Can XL track a multi-station assembly line, not just one machine?
Yes. XL installs per station or per line segment, so you see run/stop, speed vs rated and downtime reasons at the station level as well as the line level letting you find exactly where flow breaks down.
Can we track model and SKU changeovers as measured events?
Yes. Changeovers by model, variant or SKU are auto-detected by XL and split into planned vs unplanned in OEE IntelliSuite, with reason codes tied to your product mix.
How does this help with line balancing?
Station-level speed and downtime data shows exactly where stations are starving or blocking each other, so you can rebalance cycle times with evidence instead of guesswork.
Do you integrate with our ERP and MES?
Yes. OEE IntelliSuite integrates with ERP (SAP, Oracle and others), MES, SQL, MQTT/OPC and Power BI. See the Integration Tools page for details.
Can we prove the value before we commit?
Yes. We offer a 45-day free trial on one line often the highest-throughput packaging line and a Performance Audit that measures your hidden capacity in about a week.
Let’s Look at Your Assembly Line
Book a live demo with an XL scoreboard mocked on your product mix or start with a 45-day free trial and prove the value before you buy anything.