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Introduction
It is a global tier-1 automotive component company. They design, manufacture and supply lighting systems, plastic & polymer components, electrical components, and precision metallic components to automobiles, two and three wheelers and off-highway vehicle (“OHV”) OEMs directly worldwide.
Challenges
Manufacturing industry is undergoing a lot of automation and for any successful manufacturing firm, it is very important to find a new way to streamline its operations and reduce the costing. Along with the tangible aspect there are financial and managerial aspects to oversee with a perpetually changing market demand and aggressive competition. Improvement areas for the company lied in Operation and Production. Various Operations modules needed a deep analysis for systematic functioning The following modules were in special need of thorough check and improvement:
- Planned V/S Produced Quantity of goods.
- Monthly Loss Revenue
- The PPM(Parts Per Million) trends
- Cost of Poor-Quality Material
- Plant Wise Reworking Amount
- Plant Maintenance Spare Consumption
- Downtime loss in Hours
- Overall Equipment Effectiveness
- Overall Production Effectiveness
- Sales Details plant wise
Company Profile
Industry:
Auto Technology
About Qlik
Industry:
Qlik is a leader in data discovery delivering intuitive solutions for self-service data visualization and guided analytics. Over 34,000 customers rely on Qlik solutions to gain meaning out of information from varied sources, exploring the hidden relationships within data that lead to insights that ignite good ideas.
The Solution
- In a production and manufacturing unit there are a series of processes going on in parallel and it generates a huge volume of data ranging from machine run-time to no. of units produced to number of sales generated. Our client implemented Qlik Sense to decouple, analyze, and resynch together all their systems resulting in a powerful outcome.
- Insights on Production v/s Sales, Plan vs Dispatch vs Product Quantity, Total sales, Unit planned amount, Scrap amount, Rework amount, Stock mismatch, In-house rework PPM and Line rejection PPM in Qlik Sense helped them take critical decisions that optimized efforts.
- Overall Equipment Efficiency is measured upon availability, performance and quality. The dashboards display the OEE trends Plant & Work Centre wise resulting into a low-cost maintenance and timely servicing of the equipment's.
- The updated Equipment reports automatically helped in curbing down the cost of poor-quality production hence reducing the number of spare units manufactured throughout the divisions and saving a great deal of over production and wastage.
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