The new reality: Saving without sacrificing quality
In this last difficult year, in the “new reality” stage, many companies and factories are exploring and implementing cost reduction strategies. Nothing escapes analysis, all costs are analyzed and all costs that can be cut are cut. But what about quality?
In this case, it all started with the start-up of the first lighting product in the Flexngate Plastics division in Sabadell. This project required recording the quality control data on a computer and saving them in Excel format, so that both the results and the statistical calculations of the process were visible at the end of the line.
The Initial Challenge: Digitizing a Dimensional Control
The process to be optimized was a dimensional control to caliber of 8 Gap and 11 Flush control points, as agreed with the customer, it is a high frequency control process in two references (right and left). Without digitization, the data would be collected on paper, then an operator would pass them to Excel and then analyzed. The control process would be slow, and this time would be spent repeatedly several times in a production shift, the results of which would not be traceable and could hardly be consulted in real time; the record would serve mainly to fulfill the customer file.
In order to take a step further towards Industry 4.0, Flexngate Plastics in Sabadell assessed the implementation of a Quality Management System (QMS) and implemented the Kapture.io solution.
This solution includes the digitalization of the data collection through Bluetooth instruments and an automatic upload of the data to the cloud platform (AWS), reducing the cycle time by 75%, and facilitating statistical analysis and alarms in real time. The ROI of the project was obtained basically only in the time savings of a specific control process for a reference. To these savings must be added the cost reductions from taking decisions and corrective actions when problems arise, thanks to alarms and automated control and analysis mechanisms.
“Implementing a quality control tool can reduce cycle times by more than 75%.“
Digitization through Kapture.io Quality Management System
This digitalization was Flexngate Plásticos Sabadell’s first foray into what is commonly called Quality 4.0, where small changes can have a big impact. After the success and savings obtained with this process, other areas of improvement were prioritized where the application of a QMS such as Kapture.io would have a great economic impact. Among other processes, we digitized the flying controls, production controls… through different forms such as heat maps in visual controls or listings in audits.
Previously, quality control processes in injection and assembly were reported on paper and Excel, making it difficult to analyze and have a global view of the associated non-quality costs. A simple question such as: How much does the scrap of the injection process cost me per reference in the night shift? What is the Pareto of defects in assembly this morning? Has the start-up control been performed when the mold has been changed? These seemingly simple questions were laborious to answer.
Currently, Kapture.io has become the hub from which quality is analyzed, detailing the defectology by process, root cause analysis and the cost of scrap. scrap according to different parameters and attributes. Both scrap parts and rework are reported and the quantity and cost of scrap per reference, per process, per shift, per machine, per cavity is known at all times. In addition to triggering alarms and notifications according to predefined parameters.
Impact of Digital Transformation
The digitization of the different quality processes on a single platform facilitates access to data, alarms and, above all, analysis. From global tools for visual analysis in real time, to detailed analysis of when, who and how each quality control was executed, being able to dedicate resources to intervene and reduce these amounts.
The impact? The savings range from the cost of the operator doing redundant and non-value-added processes, to the non-incurred costs of scrap parts thanks to resolving incidents early or, failing that, immediately.
Flexngate has positioned itself as a leading company in innovation, digitization and quality control management and has even been recognized for its Continuous Improvement strategy in the last IATF 16949 audit for the successful implementation of Kapture.io for the digitization of online documentation.
“Digital transformation of quality reduces costs in both quality control and manufacturing processes“
Going back to the initial question, how can you save with quality, the answer is simple, there is room for improvement and obvious savings, with solutions that have an ROI of a few months. It is an opportunity for savings through investment rather than cuts, giving visibility to hidden data, facilitating feedback to the production process and bringing us closer to zero defects.
