Error Proofing

Industry Challenges

OEMs’ quality standards are higher than ever. This coupled with lower on-site inventory levels, has automotive suppliers implementing IT solutions to help eliminate errors before they occur. Today, automotive OEMs require zero defects from their suppliers. This mandate is forcing tier one suppliers to prevent non-conforming product from ever leaving their docks, or risk being assessed back charges, or worse, losing business.

Exceeding high OEM quality expectations and preventing mistakes is especially challenging for tier one suppliers today given:

• Increasing variety of products and components
• Make-to-order requirements
• Transient workforce and employee retention
• The need for employees to master complex equipment and processes

In addition to ensuring quality, tier one manufacturers are required to document quality. Lot and sub-lot traceability is required as a part of end-of-life vehicle directives that mean parts must be tracked from cradle to grave. The TREAD Act and other regulatory and customer requirements call for the early recall of defective product.

Error-Proofing Best Practice

This I/Gear Error-Proofing and Traceability module eliminates process errors and product defects from occurring and creates a permanent trail of the manufacturing process to document quality. The benefits include:

• Improve customer satisfaction
• Reduce warranty costs
• Lower ppm defects
• Reduce scrap and rework
• Improve operator efficiency

Crosschecking the part selection against the job serial number and associated bill of material from the ERP system in real time ensures quality control levels are maintained.

Root cause data can be entered to further explain the “why” behind product quality concerns – and respond quicker.