Challenge:

• Manual logging & entry of defects – communication gaps, lack of authentic data, rework downstream.
• High number of models & variants with relevant checklists not available at assembly line inspection points – key checks missed leading to additional rework.
• Instances of Tractors being certified as Quality-passed despite open defects – these were detected later in the field.

BorgConnect® Solution:

• Tablet-based BorgConnect® app for scanning tractors at each station.
• Enforcing check point adherence with digitally available checklists.
• Automated defect logging & closing (with photo capture), real-time notifications to proper rectifiers, and automated printing of ‘Quality OK’ stickers.

Results:

• Single source of truth – all data was thus accurate & authentic.
• Defects were caught upstream, rectified immediately, and no tractor left the assembly line until all defects were closed.
• The percentage of tractors going through defect-free improved by 60% - OEM now aiming for 100%.

Challenge:

• Manual monitoring of energy use – time-consuming, inaccurate, and resource-intensive.
• High utility penalties due to addition of new equipment and production activity expansion.
• Inability to extract energy data from equipment – either meters or legacy assets.

BorgConnect® Solution:

The Edge Device integrated with all plant energy meters for 24x7 kW, kWh and energy intensity tracking and smart analytics at the individual machine level.

Results:

• 12-15% reduction in energy costs in 6 months.
• Elimination of utility penalties from 2 per month to 0.
• ROI < 1 year.

Challenge:

• Lack of real-time visibility to make informed decisions for improving productivity or reducing waste – unable to meet client schedules.
• Material loss accounted for ~10% of profit margins in value.
• High material waste with poor tracking – perennial need to procure material at high cost and short notice from suppliers.

BorgConnect® Solution:

• IoT platform for smart Short Interval Control.
• Connecting non-invasively to plant floor equipment.
• Continuously track waste in materials, energy, production, quality.

Results:

• Material Wastage reduction of 30% - 2% increase in profit margin.
• Real-time traceability enabled proactive interventions & adherence to production targets.
• Critical remote monitoring capability for management into plant performance.

Challenge:

• 400 parts suppliers, each following their own quality control plans instead of the OEM’s.
• Supplier inspection checks were subjective – no traceability & prone to errors.
• OEM had to perform post-delivery checks which yielded high number of defects – expensive and production-impacting.

BorgConnect® Solution:

• Real-time integration of OEM-supplier QA processes,
• OEM remote visibility,
• Digital measurement instruments and a tablet app that digitized supplier checks while flagging non-conformance to OEM standards.

Results:

• OEM achieved zero defective parts per million within 3 months.
• OEM’s concurrent remote visibility eliminated post-delivery checks (non-value-added activity) & enabled a true picture of quality.
• Digitalization at suppliers led to improve labour productivity, training, and quality practices.

Challenge:

• Unplanned conveyor stoppages impacting production – 20% of overall unplanned downtime.
• Reason(s) for downtime logged subjectively at end of day.
• No real-time downtime visibility – reactive intervention.

BorgConnect® Solution:

• Using the edge device to collect conveyor downtime data.
• Enabling real-time visibility and stoppage classification to plant managers
• Applying machine learning of emerging conveyor failures for proactive maintenance

Results:

• Elimination of unplanned idle time by 30%.
• 50% reduction in conveyor Mean Time to Repair.
• Expected cumulative reduction in overall unplanned downtime – 80%.

Challenge:

• Significant errors & omissions by operators in bogey inspection checks.
• Cumbersome measurement process, with two-day latency in reporting inspection readings.
• Inaccurate data capture – no meaningful analysis.

BorgConnect® Solution:

• Tablet-based software for automated capture of key measurement data from digital devices e.g. callipers.
• Digitized reporting, with live defect flagging and compliance checks at all bogey inspection check points.
• Link identified defects with their suppliers for proactive corrective action.

Results:

• 30% reduction in Cost of Quality.
• 60% improvement in defect-free parts from suppliers.
• Elimination of errors due to manual data entry – improved productivity.