CASE STUDIES

TIER 1 AUTOMOTIVE  – Water Pumps

Tier One Automotive Supplier
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  • Out of date spec.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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The image demonstrates how quality results can be entered via touch screen, with in-context work instructions for each step in the check

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.)

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.)

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.

The Production Management Tools of 10in6

The Production Tools of 10in6

IMPROVE EFFICIENCY

Production Reporting (OEE)

Andon Calls

Constraint Manager

Real Time

IMPROVE QUALITY

Track & Trace

Visual Inspection

Scheduled Checks

SPC

IMPROVE OPERATIONS

Issues Tracker

Schedule Execution

Attendance & Skills Tracking

Key Supporting Features:

Analytics

THE MOST POWERFUL REPORTING TOOL EVER CREATED TO ANALYZE YOUR UNIQUE DATA

Operator Console

ONE SIMPLE, TOUCH-SCREEN INTERFACE SPECIFIC TO THE NEEDS OF YOUR MACHINE/LINE

Alerts & Alarms

ISSUE ALERTS AND ALARMS BASED ON REAL-TIME STATUS OR TRENDS USING MUTIPLE STREAMS

Real Time

PROVIDE LIVE FEEDBACK ON PERFORMANCE AND GIVE YOUR TEAM TARGETS IN REAL TIME

WANT TO LEARN MORE?

10in6 Inc

PO Box 36021
Talbot Village PO
London, Ontario
Canada, N6P OC4

  Send Email :  [email protected]

  1-519-661-1001

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    10% Improvement in 6 Months