Case Study
27%
Reduction in Quality Issues
24%
Decrease in Transformer Production Time
16%
Decrease in Order Backlogs
Challenge
Our customer is a global technology leader specializing in energy systems and solutions. The company focuses on advancing sustainable energy technologies to enable a more reliable, efficient, and secure power system.
The company faced several challenges associated with manual production tracking and quality inspection processes, including:
- Production tracking and Quality inspection processes were done manually, on paper.
- Operations team left with little visibility into Production status and Quality issues.
- Required tasks or inspections could be by-passed while other non-applicable requirements fostered a lack of discipline.
“Relying on paper-based production tracking and quality inspections left us with limited visibility into real-time production status and emerging quality issues. This lack of transparency not only allowed critical tasks or inspections to be bypassed but also caused inefficiencies where non-applicable requirements took precedence.”
North American Quality Manager
Solution
The company adopted a Connected Quality solution from ETQ and Augmentir to address challenges in their production tracking and quality inspection processes. The decision to implement Augmentir stemmed from the need to modernize and enhance their operational efficiency while supporting their commitment to delivering reliable and sustainable energy solutions.
Key aspects of the solution included:
- Deployment: 7 months to convert entire manufacturing line to Augmentir
- Use Case: Manufacturing assembly heavy equipment – Transformer
- Ensured continuity and connectivity across departmental procedures.
- Departments are now connected resulting in miscommunication and data errors .
- Present only the relevant information at the right time at the right place to support process discipline.
- Single pane of glass for custom, engineered-to-order requirements, training, work instructions, and task completion.
- Foster high confidence that essential safety instructions, PPE, and required tasks are followed.
- Eliminate paper inspection cards and non-applicable steps/checks while adding customer-specific requirements.
- Provide real-time monitoring of production execution.
- Provide easily accessible work instructions at the shop floor.
- Provide operator access to training aids and facilitate the training requirements and status of operator qualifications.
Results
By adopting a Connected Quality solution from ETQ and Augmentir, the company was able to transform its quality management processes, ensuring higher operational efficiency, improved compliance, and alignment with its vision for advancing sustainable energy technologies.
- Standardization, real-time updates (process/time savings), eliminated manual data entry, reduction in scrap
- Time to complete a new transformer decreased by 24%
- Decrease in order backlogs down 16%
- Quality issues decreased by 27%
- Troubleshooting and knowledge management around all given manufacturing processes as a means to make all workers more autonomous/ interchangeable
“With Augmentir, we’ve achieved a seamless connection across departmental procedures, ensuring continuity and eliminating the miscommunications and data errors that plagued us before. By presenting the right information at the right time and place, we’ve fostered process discipline and built confidence that critical safety instructions, PPE requirements, and essential tasks are followed without exception. The single pane of glass interface has streamlined everything—from custom, engineered-to-order requirements to training, work instructions, and task completion. Real-time monitoring of production execution and easy access to training aids on the shop floor have empowered our operators, ensuring they are well-prepared and qualified to meet our exacting standards while eliminating outdated paper-based systems.”
North American Quality Manager
