CASE STUDY IN CAR INDUSTRY

CONTEXT

A French car manufacturer has several factories which produce and assemble vehicle parts. The company is a world leader in this field but is facing increasing competition. Therefore it decided to further digitalise its factories in order to improve the efficiency of its equipment and remain competitive.

The company wanted to be able to track the performance of their machines producing mechanical parts (gears, shafts, hub carriers, etc) in order to better identify root causes of areas lacking productivity.

CHALLENGES OF A WORLDWILDE CAR MANUFACTURER

1-01

Diversified machine park
and very different production
steps

2-01

Several older machines
with limited connectivity

3

Time saving concern
and prohibition to open
the cabinets

4-01

Controlled costs and  very strict investment criteria

TEEPTRAK IMPLEMENTATION

The PerfTrak technology was challenged to connect ninety machines within a few weeks. The systems automatically identified stoppage durations and their respective root-causes. Forty monitoring screens were also deployed in workshops to visualize key production information.

Because of project size and deployment urgency, the operators were trained by the TEEPTRAK team over three days to correctly install and use our systems. After this training, the client’s teams were able to implement and configure additional systems across the whole factory by themselves without external support.

5

Implementation in 6 plants

6

Wide deployment in a few months

7

100% external integration

8-01

More than 150 connected workstations

9

More than 40 supervision screens

10-01

3 days training in installation/use

RESULTS

This installation monopolised time savings and reassigned operators on improvement missions rather than putting them on formerly time-consuming reporting tasks.. Operators now feel even more involved than before in the factory’s continuous improvement processes thanks to the Internet of Things. This is helping the factory to pursue its digitalization in a lasting manner.

11

Return on investment in
less than 1 year

12-01

Freeing up operators’
working time

13

Reassignment of operators to improvement actions

14-01

Valorization, empowerment and involvement of operators

“PERFTRAK systems paid themselves simply by freeing up people that are now able to focus on Value Added tasks instead of
collecting data and preparing periodic reports”