Published: Dec 9, 2024
Reading time: 4 min
Introduction
Automotive companies lose over $500 million each year because of outdated tooling management systems. JLR faced these same issues before we started their tooling digitalization journey. The resulting collaboration reshaped how they handle their manufacturing processes and work with suppliers.
Digital Transformation Strategy
We started the digital transformation strategy by reviewing JLR’s existing tooling management setup. The original measurements showed machine efficiency rates of 50-60%, which revealed room for improvement in their manufacturing operations.
Assessment of Legacy Systems
The existing tooling asset tracking and performance monitoring capabilities had major gaps. Because they lacked up-to-date data visibility and used reactive maintenance approaches, production inefficiencies, and supplier coordination challenges increased.
Implementation Roadmap
An integrated sensor network became the centerpiece of the transformation roadmap. The team launched the pilot project by installing advanced sensors on the JLR’s dies and added Tooling Matching Devices (TMD) to continuously connect die-cast machines and their matched tools. This reliable setup now monitors the following critical performance indicators:
- Tooling Lifecycle and Die Replacement Tracking
- Preventive and Corrective Maintenance Management
- Real-time Production Performance Metrics
- Product and Parts Capacity Analysis
- Cross-facility Communication Protocols
Stakeholder Alignment
The core team participated in extensive training sessions in all business areas to smoothly adopt the new digital tooling system. This shared approach helped achieve 72.5% overall efficiency in the original phase, which was a notable improvement from the baseline measurements.
eMoldino’s digital tooling strategy has built a foundation for informed decision-making throughout JLR’s manufacturing network.
Real-time Monitoring Implementation
JLR’s strategy focused on building out an extended network of sensors and data collection points that work naturally with their manufacturing facilities.
Sensor Deployment Architecture
Our sensor network can cover up to 200 sensors per terminal, and each terminal covers a radius of up to 230 meters. Wireless IoT sensors are fitted to the sides of the tooling to monitor operations thoroughly.
Data Collection Framework
The data collection setup transmits data securely over wireless connections. The system tracks critical parameters like shot count, cycle time, temperature changes, and location in real-time. The system has reached a 98.5% within-tolerance rate for cycle time compliance, which shows how precise the monitoring has become.
Integration with Existing Systems
Together with JLR, we built a cloud-based analytics platform that merges with their manufacturing infrastructure without disrupting current IT systems. The implementation of the TMD (Tooling Matching Devices) ensures machines communicate precisely with their matched tools. This creates a unified digital ecosystem that supports the entire manufacturing operation.
Performance Optimization Results
The new digital tooling system has made a big difference in performance. The detailed tracking and improvements have led to better efficiency, higher quality, and lower costs.
Machine Efficiency Improvements
Overall equipment effectiveness (OEE) jumped from 50-60% to 76% after they started using the new system, with certain toolings increasing final efficiency by up to 17.9%:
Scrap Rate Reduction Metrics
The digital tooling solution has significantly improved production quality. The average scrap rate dropped from 24.2% to 16.1%, an 8.1% improvement.
Cost Savings Analysis
The better use of their tooling assets has saved JLR money in several ways:
- £608 weekly savings on energy costs by reducing scrap and improving efficiency
- Machine rates have gone down by £4,791 per week
- Tooling Life has been extended, leading to up to 13% CAPEX gains
- Daily delay reduction meetings are made redundant, which makes operations run smoother
Supplier Relationship Enhancement
The tooling digitalization initiative has fundamentally changed JLR’s supplier relationships. They shifted from reactive problem-solving to proactive teamwork. Digital tooling technology created unprecedented transparency and streamlined processes in their supplier network.
Communication Protocol Changes
Digital communication channels eliminated daily delay-reduction meetings. Suppliers now share production metrics instantly, which increased their efficiency from 62.8% to 80.7%. The system automatically flags issues like cycle time deviations and allows quick responses instead of waiting for scheduled meetings.
Data Sharing Framework
JLR & its suppliers now have real-time visibility into:
- Production performance metrics and cycle time compliance
- Tool life monitoring and maintenance schedules
- Scrap rate analysis and quality metrics
- Capacity utilization and planning data
Collaborative Decision Making
Our digital tooling platform enables informed collaborative decisions with suppliers.
Suppliers’ access to up-to-date tooling data created a transparent and efficient manufacturing ecosystem. This approach improved operational metrics and strengthened supplier partnerships through shared visibility and joint problem-solving.
Conclusion
JLR’s digital tooling upgrade shows how data can modernize manufacturing. The team started with 50-60% efficiency rates and made significant gains through digital systems and supplier teamwork.
An initial trial sensor network and live monitoring system brought measurable results:
- Machine efficiency increased to 76% overall equipment effectiveness
- Scrap rates decreased by 8.1%
- Supplier efficiency improved from 62.8% to 80.7%
- Annual cost savings reached £575,700, calculated based on an initial small trial sample
These results mean more than just numbers. With more comprehensive implementation, the digital system will create clear visibility between JLR and its suppliers.
About the author
eMoldino
eMoldinoeMoldino aims to digitalize, streamline, and transform your manufacturing and supply chain operations. We help global manufacturers who want to drive corporate innovation while maintaining the core values of collaboration and sustainability. Talk with us to learn more →
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