The development and implementation of a production information collection and reporting system

Abstract

Production information, which includes production counts and line downtime information, is of great importance for automobile assembly plants to diagnose equipment problems and improve line utilization. Outdated information systems at many manufacturing plants are not capable of providing accurate production information in a timely manner. This thesis is a thorough account of an internship project conducted at Ford Motor Company's Kentucky Truck Plant (KTP) which turned a spreadsheet-based production information system into a relational database application, called PICRS. The first part of the thesis introduces the reader to the background of the internship project, focusing on the importance of accurate and timely production information and the inadequacy of the old system. The second part talks about the development of PICRS. Descriptions about system development approach, software and hardware considerations, database design, and interface design revolve around the low cost, usefulness, and ease-of-use of PICRS. The third part of the thesis recounts the implementation process of PICRS and discusses its benefits and impact on KTP's final assembly area. Lessons and observations on leadership, change management, and corporate culture, as mostly obtained in the implementation process, are also discussed in this part of the thesis.