Hold takt time without shipping a defect

“A supplier lot came back bad and we cannot tell the customer which parts it went into.”

We bind incoming lots to finished part identifiers through every operation, using RFID or scanner reads at material load and PLC-triggered events at each station. Containment becomes a filtered list instead of a shift of production.

“Our downtime data is a spreadsheet a supervisor fills out at the end of the shift.”

Downtime typed in from memory is fiction by the time it reaches a Pareto chart. We capture state changes, fault codes, and cycle times from the PLC and drives, then ask operators to classify only what the system could not attribute.

“An operator can install the wrong bracket and nobody sees it until final inspection.”

That is a poka-yoke problem, usually solvable in one station: barcode or RFID verification of the presented part, a vision check for presence and orientation, and a PLC interlock that holds the fixture until both agree.

“Launch is in five months and our critical dimension is still checked with a manual gauge.”

We design in-line measurement — vision, laser, or contact probing depending on the tolerance — and design it to be provable. Capability and Gage R&R data on your parts comes before handover, so the gauge supports the PPAP submission rather than becoming a finding in it.

“Our customer wants torque data on every fastener and the tool controller only keeps the last few thousand results.”

Tool controllers are built to fasten, not to archive. We pull torque, angle, and result status from the controller over its open-protocol interface or fieldbus as each rundown completes, bind it to the part identifier at the station, and store it with the rest of the genealogy so the record outlives the controller's buffer.