Case Study

Context: A prominent global mobility company engaged in the production of various power components across Europe, the Americas, and Asia.

Challenges: Despite having established a robust foundation for manufacturing control through modern automation, robotics, process control, and MES (Manufacturing Execution System) across all sites, the client faced two critical issues:

1. Human Operations: While automated processes were well-controlled, the management of human operations, including training and certifications, was not systematic. This oversight posed significant safety and quality risks and, in certain business areas, constituted a compliance issue.
2. Complex Machine Settings and Process Monitoring: Certain manufacturing processes necessitated complex machine settings and rigorous process monitoring. Previously, these activities were managed via paper-based systems, leading to excessive scrap at best and potential client claims at worst due to inadequate process formalization, monitoring, enforcement, and alerting.

To address these issues, the client sought to integrate the Bridge solution with their existing MES and automation systems to achieve the following:

• Training and Certification Programs: Definition and execution of training programs with integrated certification processes.
• Production Interlocking: Implementation of various checklists for machine state changes, new product introductions, and periodic quality checks.
• Operator Certification Verification: Ensuring production interlocking if operators on the lines are not certified, with provisions for routing to training and/or supervision by certified operators.
• Machine Setting Validation: Validation of machine settings, capturing machine parameters, snapshotting, alerting, and potentially interlocking production lines in case of non-compliance with specifications.

Bridge Enablers that facilitated this rapid and secure initial project include:

• Agility through Business Team Implementation: The solution is designed for implementation directly by business teams, ensuring maximal agility.
• Flexible and Packaged Solutions: The out-of-the-box solutions are highly flexible and configurable by process owners without necessitating core development.
• Rapid Installation: Bridge can be installed within minutes or operated in the cloud, obviating the need for complex infrastructure work.
• Seamless Integration: The solution integrates swiftly with various systems, including SAP, Apriso, Google Workspace, Office 360, OPC-compatible devices, NFC tag readers, and scales.
• Multiple Digitalization Pathways: Bridge offers diverse methods to digitalize processes, catering to different organizational maturity levels and facilitating continuous 

Outcome: The pilot project, encompassing data preparation, system configuration and integration, and user training, was successfully executed within a span of nine weeks. 

Two years later, Bridge has been deployed across 25 sites worldwide and became the Group quality standard solution.

The rapid implementation was pivotal to the success of the client’s digital transformation, providing quick validation and tangible business results, along with low upfront investment, self-funding initiatives, and solid ROI.