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Objective Improvement Indicator number 3: 45% reduction in average repair times

  • DATA COLLECTION METHODOLOGY.
    • The following statistics were produced by accessing the production environments of those customers who participated in this case study.
    • Our products have a transaction LOG, a logbook from which it is possible to take measurements prior to the start and use of our products, and thus trace the evolution achieved over time.
    • For confidentiality reasons, we do not name customers, the repair centers or plants where each piece of data collected was produced.
  • STATE CALCULATION BEFORE USING OF OUR PRODUCT.
    • The collection of metrics related to the reduction of average repair times prior to the implementation of our product was based on 3 sources:
    • Manually-done spreadsheets and their comparison with the delivery or dispatch orders.
    • Tracking of an ERP service order number or workshop’s own work order (when it was possible).
    • Analysis of the variation in days between the first promised date and the final recorded date (supported by legacy systems / spreadsheets).
  • USAGE TIME IN CUSTOMER DATABASE.
    • Months of USAGE: 380
    • Processed WO: 1,244,580
    • Scheduled tasks: 19,913,265
    • Quality controls (checklist): 842
    • Plants/Workshops: 21
    • Users: 750
    • Planners: 18
    • Integrated ERP: 4
  • OBJECTIVE IMPROVEMENT
    • a 45% reduction in average repair times
    • It reduces or eliminates idle time
    • It reduces or eliminates the use of overtime hours.
    • Decreases direct cost per repair.
    • Increases overall shop productivity .
    • Optimizes the need for and dedication of technicians and shifts .
    • Increases the active usage time of eachpiece of equipment.
  • FUNCTIONS OF OUR PRODUCTS THAT DIRECTLY CONTRIBUTE TO SUCH IMPROVEMENTS
    • The “task scheduler” is an optimized planning engine for the IDEAL order and sequence: the collaboration between the different technicians involved in each repair is carried out in the most efficient way possible, and with them, the overall times of each task flow of each repair are reduced to a minimum.
    • The “tasks network” tool is the skeleton that allows defining each workflow necessary for each repair. With this tool, each part coming in for repair is automatically identified and its repair flow is clear and known by everyone in the workshop. This improves productivity and increases the % of compliance with delivery dates.
    • The flexibility of the WebChecklist tool, which allows the creation of forms in a dynamic way and uses them to perform validations and take measurements at the time of repairs. Such a tool is the ideal complement to alert or stop a repair workflow if edge conditions are breached. Web Checklist provides efficiency and control in the workshop, preventing avoidable errors that result in duplication of work and downtime.
    • The visual tools “task board” “WO board” are made available to technicians to allow them to have at hand the standards defined by the manufacturer for each repair, and to download video tutorials and images to maximize their efficiency. As a consequence, technical doubts as well time lost in the search for appropriate support are eliminated, which has a direct impact on the total repair time.
    • “The online request module” avoids errors in spare parts requests, preventing the productivity loss associated with delays during the replacement of a damaged part and, consequently, the extension of the duration of the operating task.
    • “The container management module” organizes the parts that result from disassembly by placing them in containers with QR codes, thus avoiding delays and productivity loss during repair.
    • Widgets created by each user based on their preferences provide the operator with the information they consider most relevant and thus improve productivity.

More? QPLUS QPSuite is completely designed to bring efficiency to the workshop. (https://qplusglobal.com/eng/qpsuite/ )