Industrial components manufacturer
The plant knew how many parts came out each day, but not why they were rejected or where. Now it sees it as it happens.
The challenge
15% rejection rate with no idea which shift, machine or product it came from
The solution
Line data capture, shared quality metrics and a shop-floor screen with visual thresholds
How we did it
We connected the line data capture and the quality control records, which until then were written on paper and typed up once a week. From there we defined the quality metrics once and for all: rejects by shift, by machine and by product reference, with the same calculation rule for everyone. The shop-floor screen shows the state of each line with visual thresholds, so a deviation is visible from the other end of the workshop without reading a single number. Supervisors get the shift detail as it closes, and the quality team works with the history to see which references concentrate the problem. The project includes no predictive component: the improvement comes from seeing deviations in time and working from the same figure.
Results
Project timeline
Map of line and quality control records
Quality metric dictionary
Shop-floor screen with visual thresholds
Shift report for supervisors
Testimonial
“The numbers were always there, but nobody looked at them until Monday. Putting the screen on the shop-floor wall instead of in an office was their proposal, and it was the right one.”
Services used
Data ingestion & integration
We connect the systems where your information already lives and bring it into one place, automatically and repeatably.
Data model & metrics
We define your business metrics once, so everyone is talking about the same number.
Dashboards & visualization
We design screens that answer specific questions: what happened, where, and what to look at now.