CASE STUDIES

TIER 1 AUTOMOTIVE – Water Pumps

man turned away walks through large automotive manufacturing plant with beams, buttons and machinery in foregrous

Learn how a Tier 1 Automotive Supplier improved First Time Quality and OEE with 10in6 Scheduled Checks and Production Reporting

“Like most plants, we have many lines and many issues, but limited resources. Our engineers could walk around the plant and find things to fix all day. 10in6 helps us to focus our team on the highest impact issues, so we get the most value from our engineers.”

Engineering Automation Manager, Tier 1 Automotive – Fluid Power Solutions

BUSINESS OUTCOMES

The production team is able to complete quality checks quicker due to the presentation of Work Instructions, ease of data entry and automated SPC charting of results. The Quality team can now analyze trends to focus improvement on the right issues, resulting in a higher FTT metric.

Reduced time to complete quality checks = more time to produce
Quality Data now used to improve quality, not just for compliance

Improve FTT by 11% and OEE by 12% in first 6 months
Automated production reporting to focus resources on key issues

“The automated SPC charting, alerts and quality reports help the quality team to react quickly and focus on the exceptions, like out of spec processes or lines where checks are being missed.”

Production Manager, Tier 1 Automotive – Fluid Power Solutions

“The automated SPC charting, alerts and quality reports help the quality team to react quickly and focus on the exceptions, like out of spec processes or lines where checks are being missed.”

Production Manager, Tier 1 Automotive – Fluid Power Solutions

CHALLENGES

Production staff were spending too much time executing the quality control plan for ISO. While their efforts met the ISO requirements, they provided little value to the Production and Quality team to improve First Time Through (FTT).

Like many automotive plants, production staff on the line not only run the processes, but also complete in process checks to ensure product quality and compliance. With paper based tracking and manual plotting of control data, operators were spending more time than needed to complete checks. In addition, production data and losses were being tracked manually, providing no real-time feedback or trended data to focus improvement.

Paper-based, time-consuming quality checks

Manual Control Charts, 20 to 30 data points per part
Providing no value to Production or Quality (paper filed away)
Out of date spec. sheets circulating in plant

Paper tracking of production counts and losses

No real-time feedback
No easy way to analyze data for trends

“10in6 is a catalyst for the manufacturing team. Quality, Engineering and Maintenance are all using the same data, working with a more united focus on the issues.”

Engineering Automation Manager, Tier 1 Automotive – Fluid Power Solutions

“10in6 is a catalyst for the manufacturing team. Quality, Engineering and Maintenance are all using the same data, working with a more united focus on the issues.”

Engineering Automation Manager, Tier 1 Automotive – Fluid Power Solutions

SOLUTIONS

This customer first implemented the 10in6 Production Reporting module for comprehensive tracking of losses and real-time visibility of production. They then added 10in6 Scheduled Checks to provide paperless tracking of all in-process and start up checks, including electronic work instructions to ensure checks were completed on time and correctly. The customer completed 75% of the implementation themselves after 10in6 staff trained them on a small set of checks.

Production Reporting (OEE)

Real-time feedback on production
Comprehensive loss tracking (not just downtime)
Automated Production Reporting
Easy to analyze data to find trends and focus improvement efforts

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Scheduled Checks

Alerting for quality checks due, late or missed
Simplified data entry for operators
Latest work instructions delivered in context during checks
Searchable history to identify trends and drive improvement
All results available quickly to address customer audit requests

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Real-Time

Alerts for quality checks, out of spec results, excess down-time and more
In plant display boards to drive accountability
Mobile views for visibility anywhere inside or outside the plant

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SPC

Automated plotting of all numeric quality check results
Alerting of out of spec. conditions

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A screenshot of a digital quality check within the 10in6 software. Instructions are provided on the left and numeric input is provided on the right

The image demonstrates how quality results can be entered via touch screen, with in-context work instructions for each step in the check

A screenshot of SPC within the 10in6 Operator Console, displaying the measurement of height over time in a line graph

Automated control charts are plotted for each variable – with alerting enabled for out-of-specification results. (All results are available in the database for analysis and trending by machine, operator, part number, etc.)

A line graph showing quality % increasing over a 6 month period for the '10R Main Line' area

A line graph showing OEE over time, increasing from 32% to 55% for the '10R Main Line' area over 6 months

Analytics Reporting – OEE performance for the same 6 months shows improvement from 32% to 54%. The simultaneous improvement in FTT (image above) tells us the line was stopped fewer times for out-of-spec issues, and fewer parts needed to be reworked.