Automotive OEM Success Story
Varied responsibilities burdened the supplier quality assurance team of this global Fortune 100 automotive OEM. Complexity and data trapped on paper significantly slowed operations – until they implemented the SmartWorkStation. Read about how our digital work instructions platform helped SQA increase overall vehicle quality and satisfaction, while decreasing project time and cost.
Challenges in the Automotive Industry
Automotive OEMs and their Tier One suppliers are facing growing challenges to increase vehicle quality, while balancing production speed and accuracy on the assembly line. Recently, a Top Ten/Fortune Global 100 automaker partnered with Andonix to overcome these challenges.
Challenges in the Inspection Process
The OEM depended on its supplier quality assurance team (SQA) to address inbound defective components. This assignment impacted their day-to-day operations since the team is responsible for a multitude of tasks, ranging from initiating phone calls for collaboration between supplier and contractors to implementing permanent corrective actions to protect the assembly line. Their varied responsibilities left the SQA team spending more time on managing supplier compliance, materials management, manufacturing, and plant quality, with no time left to implement immediate corrective actions. Such actions include creating inspection methods and work instructions, training quality inspectors, managing exceptions, analyzing data and updating and managing constant changes.
Additionally, the SQA team was constantly struggling to update and replace the work instructions in several work stations spread over one million square feet of manufacturing space and ensuring the inspector job pairing was accurate despite rotation and absenteeism. Often containment projects were late and over budget with non-conforming pass-throughs to the assembly line. OEM stakeholders often lacked real-time information from the containment activities. Moreover, there was a lack of transparency on time, materials, and containment performance. Complexity and data trapped on paper-based systems left the SQA team facing a significant slowdown in how it operated.
The company was committed to aligning its containment activities to the corporation’s vision, so it started enacting strategies to increase line speed and flexibility, and to regain the effectiveness and focus of its functional goal. By choosing to digitalize the containment process, all work instructions, training, data acquisition and reporting could be performed on tablets and smartphones.
Improving Effectiveness by Digitizing Containment Work Instructions and Processes
Andonix helped the OEM SQA team during an extremely demanding vehicle launch by implementing a digital system to manage every single step of the quality recovery process. The SQA team was able to maintain a fast-paced, dynamic, and demanding environment, managing over 100 quality projects on any given day.
Andonix’s digital work instruction platform, SmartWorkStation, streamlines, organizes, and integrates all processes and stakeholders of the containment function.
Working with SWS proved incredibly easy for the team, as the solution connects all stakeholders with the process and place and supports all containment process needs. Specifically, SWS:
- Provides fully customizable digital work instructions and check lists (no programming experience needed) to enhance on-the-job training, communication and worker supervision.
- Streamlines communications by providing a digital Andon Cord that connects front line workers with relevant information to reduce delays, inefficiencies and quality gaps.
- Gives real-time data to stakeholders by providing a powerful reporting tool with data analytics to predict, prevent, prescribe and provide valuable insights for continuous improvement.
- Adds performance transparency.
- Dramatically minimizes mistakes.
In addition, the overall vehicle quality and satisfaction increased while project time and cost decreased. This returned time to stakeholders so that they could focus on their value-added functions and maintain their commitment to designing, building, and producing the best quality vehicles in the world.
SmartWorkStation is the future of the connected worker.