01 — Global automotive manufacturer
ContinuumAdigitaltwinthatturnedasix-monthretoolintoasix-daydecision
A multinational automaker used Continuum to model a full assembly-line reconfiguration before committing capital, catching a bottleneck that would have idled two plants.
02 — Challenge
The manufacturer needed to retool three assembly lines for a new vehicle platform without halting production. Every proposed layout had to be validated against real throughput, changeover time, and downstream supplier constraints, but the only way to test a layout had been to build it.
03 — Approach
JMA connected live line-sensor and MES data into a Continuum digital twin of all three plants, then ran hundreds of reconfiguration scenarios in simulation, scoring each for throughput, changeover risk, and maintenance exposure before any physical change was made.
04 — Results
0 days
to validate a layout that would have taken 6 months to test physically
$14M
in avoided rework and idle-line cost
0%
improvement in projected line throughput
05 — In their words
“We stopped arguing about which layout would work and started watching the twin show us.”
— VP of Manufacturing Operations