Construction – Reducing End of Line Rework

Key Results

• Improved Product Quality.
• Reduced end of line rework by over 50%
• Business Growth with Global Manufacturers.
• Improved Productivity.
• Improved Data-Driven Decision Making.
• Full traceability of components and manufacturing processes.

The Challenge

Husco International is a global manufacturer of control systems for off-highway vehicles and they are technical and quality leaders in their field. They have made substantial investments in several advanced manufacturing and business systems. These investments have paid dividends in providing industry-leading customer service and reliability. It has also helped Husco to demonstrate their commitment to excellence and drive a zero defects culture within their organisation. 

Husco decided to improve its manufacturing functions with connected production lines. They wanted to achieve a zero defects manufacturing process, by connecting complex manufacturing processes together. This helps to ensure that the correct components and processes are used at each stage of manufacturing. It also prevents manufacturing mistakes and defects from progressing along the production line. Consequently, Husco has been able to: 

• Implement Zero Defects Culture.
• Offer additional data products and benefits to customers.
• Differentiate from competitors.

The Solution

Husco approached us to deliver a comprehensive digital manufacturing solution that controls a new production cell for a high-profile construction client. 

We used our digital manufacturing software Tascus to control production and guide operators through complex processes, reducing training time and errors.

Husco has a wide mix of manufacturing processes and quality checks, so, we have developed Tascus to connect and control their manufacturing processes with:

• Manual operations using sensors and actuators
• PLC’s
• Smart Cameras
• Barcode Scanners
• Smart Tools. 

An integrated end of line test solution ensures that only 100% full tested and traceable products were sent to the end customer.

Each product has a full manufacturing birth record, with over 1000 data entries, giving an unparalleled level of detail about every product that leaves the factory.

Our client ensures that routine maintenance, cleanliness and calibration tasks are always up to date using our maintenance add-on that prompts, reminds and prevents missing essential tasks.

They have found they can ramp up their production whilst maintaining high quality levels, high productivity and full insight into their manufacturing process. By creating a fully connected production line, they have reduced end of line rework by over 50%.

Results

As a result, there has been an increase in product quality and an increased ability to manufacture small batches of unique components.
Since implementing manufacturing connected production lines, Husco has seen reductions in product defects and are making excellent progress towards their goal of zero defects manufacturing culture.