Stegia introduces efficient scalable manufacturing with ProcessIQ.
Faced with increasing complications of scaling assembly line operations using paper-based work instructions, Swedish firm Stegia has introduced digital manufacturing instructions with the implementation of ProcessIQ.
Cluttered paper processes
Manufacturing electromechanical motors used in a range of products from door locks to cash handling, Stegia has manufacturing facilities in Sweden and China. However, Stegia’s paper-based system for manufacturing its innovative technology products was causing complications. “We had a very manual process and version control was challenging,” explained Mats Sandvik, Lead Electronic Engineer. “The assembly instructions for each product would be printed out and we had to ensure it was stored in the correct place.
“Paper caused some clutter and we did not have a consistent approach to how our instructions were put together; created in a mix of Word, PowerPoint, and Excel. Also, the images were not always clear, and the documents used different sized text.”
Employees were unable to efficiently build, added Production Manager Mathias Dragovski: “The paper instructions used to produce a lot of questions from employees, so the line manager was required to be there to support production, answering the flow of ambiguities. There was always the risk that everyone could interpret the instructions slightly differently, so we needed to transform our operations.”
“When we looked for a new system, we needed one that enabled our workers to pick up where they left off. We did an online search for digital work instructions and ProcessIQ was at the top of the list.”
Scaling delivery
Stegia’s smaller manufacturing lines are based in Västerås, Sweden, and higher-volume assembly is located in Shanghai, China. Stegia recognised that they required a system that would allow production to scale. “Our lines are flexible with employees working an occasional week, and some on a one day a month, or two days a week basis,” said Mats. ProcessIQ was implemented in 2017 and is currently in use on two product lines, but Stegia intends to expand across its operations. Mathias explained: “The benefits of using the ProcessIQ system for production has been clear.
“It is much easier for the operators to follow each task. The instructions are clear, with images to underpin the instructions, so there is no ambiguity. We also embed video to record more tricky assembly steps. And training new staff is much easier too, especially with the use of touch screens.” “ProcessIQ enables us to be confident that we have the latest version of the work instructions on the shop floor. Version control processes are in place and any amendments can be pushed out quickly. “If we get questions from an employee, we can go back into the procedure and adjust it to clarify the steps, releasing a new version instantly. This allows us to manage risks and work more efficiently,” commented Mathias.
Impressed customers
ProcessIQ has enabled customer audits to go more smoothly. “Many customers are impressed with the ProcessIQ system. It makes us look much more professional than the previous binders full of paper,” commented Mats.
“Our paper-based system caused confusion and limited our shop floor productivity. With a clearer set of instructions in ProcessIQ, not so many questions are asked of the managers, freeing up their time to work on other tasks.”
“We look forward to additional functionality in ProcessIQ, such as collecting data which will enable us to have insightful visibility of our operations,” added Mats. ProcessIQ has enabled Stegia to benefit from improved document control and audit, electronic work instruction standardisation, and the ability to quickly adjust instruction versions, creating clear procedures whilst improving manager productivity. In addition, Stegia customers are impressed when they see ProcessIQ on the production line.
