Case Study

Context: A leading global Tier One automotive supplier, with a network of over 150 production facilities across 25 countries, engaged in the manufacture of a wide range of vehicle components, including electronic, electrical, and mechanical parts.

Challenges: Despite the implementation of advanced automation, robotics, process control, and MES (Manufacturing Execution System) across all sites, the client encountered two critical issues:

1. Human Element: With automated processes tightly controlled, the variability introduced by human factors emerged as a significant concern. The existing systems lacked the capability to formalize, trace, and interlock certifications, presenting both a quality risk and a compliance issue within the stringent regulatory framework of the automotive industry.
2. Procedural Oversight: The MES primarily manages production order execution but fails to handle other critical events such as line or machine startup and shutdown procedures, periodic or event-driven inspections, calibrations, and enforcement of safety protocols. Consequently, numerous procedures remained manual, difficult to enforce, and not systematically tracked, leading to inefficiencies, latency, and potential risks associated with paper-based processes.
   
   

Given the client’s commitment to serving a global customer base from multiple manufacturing plants, a swift and comprehensive deployment of the solution across all sites was imperative to mitigate compliance risks.

Solution: Following a successful pilot implementation, we developed a comprehensive rollout kit enabling the client’s site business teams to autonomously implement the solution. The rollout kit encompasses:

• Training Modules: Comprehensive training packages for key and end-users.
• Master Data Template: Standardized operating procedures, work instructions, training plans, and various checklists pertinent to production, quality, and maintenance-related activities.
• Installation and Integration Packages: Facilitation of machine and system integration.
• Embedded Analytics: Provision of real-time insights and data-driven decision support.

Bridge Technical Enablers: Several key enablers within the Bridge platform facilitated this rapid implementation:

• Business Team Implementation: The solution is designed to be implemented directly by business teams, ensuring maximal agility and reducing dependency on external support.
• Flexibility and Packaged Solutions: The out-of-the-box solutions provided by Bridge are highly flexible and can be configured by process owners without requiring core development.
• Rapid Installation: Bridge can be installed within minutes or operated in the cloud, eliminating the need for complex infrastructure work.
• Seamless Integration: Bridge is designed to integrate quickly with various systems including SAP, Apriso,  Google Workspace , Office 360, OPC-compatible devices, NFC tag readers, and scales.

Outcomes:

• Deployment of up to 35 sites per annum.
• Site implementations completed within a few weeks by local business teams with minimal support from the central team.
• Limited dependency on local and central IT support.
• High levels of site adoption, reflecting substantial operational agility.
• Uniformity in solutions across all sites, fostering the exchange of best practices and configuration elements such as checklists and work instructions.
• Continuous enhancement through Bridge and client-specific innovations delivered via quarterly updates.