Wagon Automotive: To manage and to control the production with zProduction


WHAT IS THE PROJECT OF zPRODUCTION INTEGRATION WITHIN WAGON AUTOMOTIVE SRL?

Due to the size and enterprise production, it was chosen to start from a pilot line, consisting of two parallel lines performing the same processing on the side members for industrial vehicles, to have a gradation in the introduction of the new methodologies and then a transition as simple as possible. In a short time zProduction has been extended to the line adjacent to the pilot and to the quality department, with the objective to get to extend its use also in the order production lines.

WHEN WAGON HAS BOUGHT zPRODUCTION, WHAT WERE THE CHALLENGES AHEAD?

Before the introduction of zProduction, the collection of production data was done wholly on paper (production film), where operators marked the information about timing and quantities produced. One production film was compiled for each round on all machines or lines; then they were delivered to the production manager who wrote out the information on Excel spreadsheets.

Also signs and notices about production were on paper, so it exposed Wagon to error risks during the information transmission. Furthermore, it passed long time from the production to its analysis, thus getting feedback in real time about performance of the several details was difficult.

Using zProduction, Wagon Automotive S.r.l. aims to:

- Optimize the accessibility and the realiability of recorded data;

- Repair the leak of information, improving the transmission;

- Remove records and notices on paper between line operators and production managers.

Before long zProduction became the reference for the management and control of production: the managers load production orders and operators record production, waste, quality control, setup times, dismantlement times, downtime production along the line. The data entered by the operators are available in real time to the office workers who can track performance and line data.

WHAT RESULTS HAVE BEEN ACHIEVED AND HOW?

We have experienced benefits after a short time from the installation of zProduction. One of the most important is the evaluation of hourly productivity of each item: after only a few weeks of use timely and accurate data have been achieved. Through them it was possible to analyze clearly the performance item by item, highlighting discrepancies and allowing an adjustment both for the planning  and for evaluation performance of each item. In addition, the schematic operations that operators must perform highlighted immediately where acting in order to improve the work operators quality.

WHAT BENEFITS zPRODUCTION BROUGHT TO WAGON AUTOMOTIVE?

The most obvious benefit was undoubtedly the streamlining operations of data recording and the drafting of reports. All transcripts of recordings from paper sheets in Excel files have been deleted, the perfomance indicators and reports are processed automatically and they are available in real time. Thank to this actions, the company has a savings of several human hours during the data entry operations, that can be used in operations with higher value added in order to increase company productivity and profitability.

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