Visteon's Sterling plant uses simulation-based decision support in training, operations, and planning

Visteon's Sterling plant uses a strategic decision support system (DSS) that integrates plant-floor information systems and simulation for three related, mutually reinforcing purposes: productivity training, productivity improvement in operations, and design of new operations. A self-directed team of the front-axle production line at the plant used the DSS to increase production of front axles for Ford Expeditions, Lincoln Navigators, and F-series trucks. Improving the productivity of this production line was important to the plant, the customers, and company profitability as the US market for high-profit margin 4 × 4 trucks and sport utility vehicles exploded. As a result of the new system, productivity improved by more than 30 percent. The plant produced an ‘extra’ 144,496 front axles between January 1997 and July 1998. The DSS was also instrumental in Visteon avoiding a $10 million modification on the line that would have been inefficient. Visteon used the DSS in designing a new line with higher productivity and $5.5 million cost savings.