The challenge
Stegia manufactures electromechanical motors for products ranging from door locks to cash handling systems, with smaller, flexible lines in Västerås, Sweden, and higher-volume assembly in Shanghai, China. Some employees work an occasional week, others one day a month or two days a week.
Printed assembly instructions had to be stored in the right place, and they were created in a mix of Word, PowerPoint and Excel, with unclear images and different text sizes. They generated a constant flow of questions, so line managers had to be on hand, and there was always a risk that people would interpret instructions differently.
We had a very manual process and version control was challenging.
The solution
Stegia implemented ProcessIQ in 2017 on two product lines, with plans to expand across its operations. Clear instructions with supporting images removed ambiguity, video captures the trickier assembly steps, and touchscreens make training new staff much easier. Version control means the latest instruction is always on the shop floor, and changes 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.
The results
With clearer instructions, managers are asked far fewer questions and have more time for other work. Document control and audits are stronger, and customers notice the difference.
Many customers are impressed with the ProcessIQ system. It makes us look much more professional than the previous binders full of paper.
Stegia is now looking forward to collecting production data in ProcessIQ for deeper visibility of its operations.
