Digital production control for automotive suppliers
A control plan with critical characteristics, SPC on the floor, an 8D report for a complaint and part genealogy from the material batch to shipment. When the IATF auditor or the OEM customer asks for evidence, you have it in a minute, not after a week in binders.
Sound familiar?
The highest quality requirements in industry, full traceability and a customer who expects a complaint answer within a day. On the left the problem, on the right what the system does with it.
The IATF auditor and the OEM customer want evidence, not declarations
The control plan in Excel, cards in binders, records from several shifts in different places. Preparing for an audit is a week of searching.
A control plan per part with CC and SC characteristics, the history of every measurement with the operator, gauge and specification, NCR, CAPA and 8D in one workflow. All with date and time, in one click.
An OEM complaint: 8D within a day
You need to find the batch, the operator, the inspection results and write a report in the customer's format before they call a second time.
You run the 8D report step by step from D1 to D8, linked to the NCR and the measurements. The batch, machine, shift and inspection results come from the part genealogy, not from memory.
Critical characteristics require SPC, and SPC lives in a spreadsheet
Control charts are made afterwards, in the office. The operator does not see the trend until a reject appears.
A characteristic has a CC or SC criticality, an I-MR or X-bar/R chart and Cpk calculated continuously. Nelson rules raise the alarm on the floor while results are still in tolerance. The capability report goes into the PPAP package.
Recall: how many pieces and where they went
One bad batch of steel or a component can mean thousands of parts. Without batch tracing you recall a whole week of production.
The material batch with the supplier's number, the parts from every operation and the shipments are linked by a scan at the workstation. From a bad delivery you get to every product batch and hold only those.
A reference change several times a day
Every changeover of a press or a welding cell is a risk: wrong program, wrong material, first piece without inspection.
A changeover has a start, an end and a plan on the timeline. First article inspection after the changeover in blocking mode: without approval the operator cannot start production.
Expensive machines are down more often than the plan says
CNC, welding robots and presses are down, and every shift explains it differently. No data to tell a breakdown from organisation.
The run signal and cycle counter from the gateway, the downtime reason from the operator at the moment of the event, from one dictionary. A loss list in recoverable hours, OEE targets per machine and the gap to target.
One shift with DiGi
Press PR-02, flanged bushing, critical characteristic: diameter. Data from the demo company.
A new reference on the press. The tablet requires a first article inspection: dimensions from the micrometer enter without retyping, the operator sees on the drawing which dimension they measure. Start only after approval.
The operator scans the label of the steel coil with the supplier's batch number. Every part from this operation has recorded what material it was made from.
Every two hours five pieces on the diameter. The X-bar/R chart is calculated from subgroups, Cpk updates after every session.
Two of the last three points beyond 2σ. The operator picks a defect and a cause, an NCR is created, the batch is on hold pending a decision. The quality manager gets an alert.
The customer reports a defect in a batch from last week. You open the batch: material, machine, operator, inspection results. You start the 8D report from ready facts.
Machine OEE for the day, changeovers over plan, open NCRs and CAPA actions with deadlines. The report arrived by e-mail before the meeting.
Modules for this industry
Every module works on its own, and together they run on one operator tablet and one register of parts, machines and operators.
DiGi Smart Control
Quality control
Quality control for automotive supplier requirements: a control plan with CC and SC characteristics, readings straight from the gauge, SPC on the floor, and NCR, CAPA, 8D and audits in one workflow.
A characteristic has a criticality, a gauge, a tolerance and an inspection moment. The operator sees only what needs measuring now.
I-MR and X-bar/R charts, Nelson rules, Cp and Cpk per characteristic, machine and cavity. A capability report to PDF and XLSX, for the PPAP package.
A non-conformance is created from an out-of-tolerance measurement, with a defect and a cause. Actions have an owner and a deadline, the 8D report has steps D1 to D8.
You build the checklist to the customer's requirements. A NOK answer becomes a CAPA action, not a note in the margin.
DiGi Smart Trace
Batch traceability
The part genealogy the OEM customer asks about: from the material batch with the supplier's number, through every operation, to shipment. Links are created by a scan at the workstation, not in a spreadsheet afterwards.
A bad part? You open the batch and see the steel or component batch, the operator, the machine and the inspection results from every operation.
A supplier reports a batch problem? The system shows every product batch it went into. You recall only those.
A delivery not released by the quality department will not reach a workstation. The batch status watches that for the warehouse.
You export the batch tree with dates, operators and inspection results to PDF with one button.
DiGi Smart Monitor
Production efficiency
Expensive CNC machines, welding robots and presses have to run. The run signal from the gateway, downtime reasons from the operator and a loss list in hours show where time leaks.
Every machine with an OEE target and the gap to target. You see whether the problem is no orders, changeovers or breakdowns.
Frequent reference changes have a start, an end and a plan on the timeline. The report shows the hours over plan per month.
MTBF and MTTR from recorded breakdowns. Missing staff, material and packaging in separate loss groups.
The shift and daily report arrives by e-mail. You set up a new report breakdown in a few clicks, without a spreadsheet.
What your customers and auditors require
DiGi does not replace your system documentation, FMEA or APQP. It provides the shop floor records the auditor and the customer ask for, with a date, an operator and a gauge.
IATF 16949
A control plan per part, records of every measurement, gauge supervision with a calibration due date, a non-conformance and corrective action workflow, process audits with a checklist.
PPAP
A Cp and Cpk capability report per characteristic and the measurement history to PDF and XLSX, ready to add to the package.
Customer-specific requirements (CSR)
An 8D report for a complaint, CC and SC characteristics with SPC, part genealogy from the material batch to shipment on a single request.
Layered and process audits
The audit checklist in the system, an OK/NOK result per item, a non-conformance turned into an action with an owner and a deadline.
Questions we hear in this industry
Yours is not here? Write or call, we reply within 24 hours.
Manufacturers that work with us
Let's talk about your production
We reply within 24 hours
Piotr will help you pick the solution that fits your production processes.
Phone: (+48) 668 211 736
Email: digismartcontrol@gmail.com