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.
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.
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.”
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.
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.
“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.
