｜Customer Background
A German manufacturer specializing in automotive parts like shafts, bushings, and hydraulic components. Known for high-quality production and strict inspection standards, the company expanded into China and entered the Japanese market, becoming a key supplier to major global car manufacturers.
｜Customer Pain Points
The automotive industry imposes strict quality standards on its parts, presenting significant challenges for suppliers. At this facility, the original quality management system operated independently, lacking integration with the ERP order system, JPI scheduling, and RQM quality control platforms. As a result, data was scattered across systems, making effective management difficult. Manual entry of measurement data was also time-consuming and error-prone, preventing efficient analysis and reporting. In addition, PQC inspections were often delayed or inaccurately recorded, impacting timely quality control. Machine wear compensation relied on manual calculations, increasing both operational complexity and the risk of errors. These challenges severely hindered production efficiency and precise quality management, highlighting the urgent need for smart automation and data-driven solutions.
｜Overcoming Challenges
SynFactory Quality Management Module, designed for the metalworking industry, helped the client achieve full QC digitalization — from inspection data to remote tool compensation and real-time quality dashboards, enabling a complete QC management cycle.
Before deployment, Leantec assisted in batch-transferring legacy system data, completing the migration of 300 material, process, and specification entries within five minutes. The solution centralized process documents (drawings, SOPs, inspection standards) for immediate access, scheduled inspection tasks with automatic prompts, and directly captured measurement data from gauges, eliminating manual entry and improving accuracy. SPC reports were generated in real time, allowing managers to promptly detect anomalies and optimize production quality.
For tool compensation in production, Leantec offers a remote tool compensation function. The Tool Compensation App automatically reads measurement files and data, allowing operators to confirm and apply system-recommended compensation values without manual calculations. This significantly reduces the risk of errors from manual input.
｜Benefits
The SynFactory solution fully integrates data flows, addressing the issue of scattered data. Digitalizing the quality inspection process unlocks smarter, more efficient workflows:
1. Digitalized Quality Standards: Converts quality inspection requirements into digital formats, supports digital measuring tools, and integrates various measurement report formats, minimizing human errors.
2. Inspection Task Management: The task warning system ensures timely reminders for completing quality inspections.
3. Real-time Remote Tool Compensation: After precise measurements, the system automatically calculates and adjusts tool wear compensation, ensuring safety and efficiency.
4. SPC/Yield Analysis Dashboard: Provides traceable and actionable product quality data, with real-time SPC charts reflecting on-site product quality for smooth production.
A small step toward digitalization is a giant leap for quality improvement. The SynFactory solution not only reduces heavy reliance on manual labor, freeing up human resources for decision-making tasks, but also empowers managers with digital analysis and statistical capabilities to quickly identify and resolve anomalies, ensuring the production of higher precision and quality products. This project marks the first step in the client’s digital transformation journey, with further collaborative plans to build a more efficient digital factory.
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