Paperless Quality Lifts First Time Through from 72% to 83%
ISO compliance that produced paper, not improvement
Production staff were spending too much time executing the quality control plan for ISO. The effort met the ISO requirements — but it provided little value to the production and quality teams for actually improving First Time Through (FTT). Results went onto paper, and the paper went into a filing cabinet.
- Paper-based, time-consuming quality checks eating into production time
- Manual control charts with 20 to 30 data points per part
- Data providing no value to Production or Quality — filed away, never analyzed
"Like most plants, we have many lines and many issues, but limited resources. Our engineers could walk around the plant and find things to fix all day. 10in6 helps us to focus our team on the highest impact issues, so we get the most value from our engineers."
Scheduled Tasks — paperless quality with built-in work instructions
The customer implemented the 10in6 Scheduled Tasks module for paperless tracking of all in-process and start-up checks, including electronic work instructions presented in context to ensure every check is completed correctly.
Notably, the customer completed 75% of the implementation themselves: 10in6 staff trained the team on a small set of checks, and they rolled out the rest — proof of how configurable the system is once a team knows the pattern.
Paperless Quality Checks
- All in-process and start-up checks tracked digitally at the line
- Electronic work instructions shown in context for each step of the check
- Quality results entered via touch screen — quick and consistent
Automated SPC & Alerting
- Control charts plotted automatically for every variable
- Alerts for failures, out-of-spec results, and missed checks
- Full history of results to spot trends and focus improvement efforts
- Analysis and trending by machine, operator, and part number
"The automated SPC charting, alerts and quality reports help the quality team to react quickly and focus on the exceptions, like out of spec processes or lines where checks are being missed."
Quality data that improves quality — not just compliance
The production team completes quality checks faster thanks to in-context work instructions, easy data entry, and automated plotting. The quality team analyzes trends to focus improvement on the right issues — and the numbers followed.
- First Time Through improved from 72% to 83% over 6 months
- OEE improved from 32% to 54% over the same 6 months — fewer line stops for out-of-spec issues and less rework
- Reduced time to complete quality checks — more time to produce
- ROI on paper waste and physical storage
- Quality data now used to improve quality, not just demonstrate ISO compliance
"We're so close to the issues now that they can't hide. When we fix something, we quickly see an impact on our overall numbers, it's very apparent."
"10in6 is a catalyst for the manufacturing team. Quality, Engineering and Maintenance are all using the same data, working with a more united focus on the issues."
Also in automotive: see how a Tier One safety components supplier scaled 10in6 across nine plants over a 12-year partnership — read the case study →
Prefer the narrative version? This story is also told on our blog: How a Tier 1 Supplier Improved FTT by 11 Points and OEE by 22 Points →
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