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Case Studies

Read how Datamyte solutions are making a difference for our clients.

SPC Standardizes Calculation for Benchmarking across plants

A net weight control program managed by SPC software and data collectors reduces waste and costs

Canada Rubber Group improves efficiency with Quality Planning Studio

A Swiss transnational food and beverage company relies on DataMetrics globally for net content management

Are You Intentionally Overfilling to Avoid a Compliance Risk?

See how this error-proofing solution upholds quality, saves time, and reduces Costs

Top automotive interiors manufacturer streamlines its data collection process

AGS Automotive plants reaps the benefits of their QPS Cloud solution

Aavid Thermal finds reliability with DataMetrics for High Mix, Low Volume production

A global tire manufacturer finds the perfect setup and standardized calculations for benchmarking processes

Challenge | Specific setup hinders evaluation and proper benchmarking
A global tire manufacturer uses a process for measuring various tire dimensions and must be able to evaluate not only the part themselves, but the process as a whole. Their challenge – creating a dynamic set-up for evaluating and properly benchmarking their end-to-end measurement processes across multiple plants. The client couldn’t evaluate a specific part without exporting and sorting the data which took a lot of manpower. They were also unable to benchmark its individual plants without using a great deal of manual data aggregation into centralized database. This manual process created ‘points-in-time’ snapshots and wasn’t able to enable a real-time view. Each plant was calculating their KPIs, independently, without consistency across multiple plants.
The Solution | Standard setup and calculation for benchmarking
Datamyte’s Consulting Services team addressed this issue by implementing DataMetrics SPC software. A CpK calculation based on standardized values was introduced allowing the Report Designer to calculate the Cp and CpK for a given process regardless of what the nominal or tolerances are for each characteristic.
Value | Efficiency, transparency and consistent quality
With this calculation, based on the percent usage of the spec limits, not the value itself, the client was able to have centralized up-to-date data aggregation and reporting through the Report Designer and Scheduled Tasks. Datamyte was also able to implement a “traffic light” at each machine showing the current CpK for that process. This report, refreshing every five minutes, giving the client full visibility into their production. If any of the “traffic lights” turned yellow, investigation begins to begin root-cause analysis. Now, the client’s global plants have a standardized calculation for benchmarking to ensure the company’s products are of the same quality.

A net weight control program managed by SPC software and data collectors reduces waste and costs

Turning a New Leaf

With a business model built on listening to customers, anticipating their needs and working closely with them to create new and innovative products, this top food processing company is also the number one food service supplier in the United States. Customers who rely on its pre‐packaged salad ingredients include several of the top fast food and restaurant chains.

“Process control, not product control” is the company’s mantra, and it has used Datamyte software for net weight control and measurement of seal integrity for over eight years.

“We perform quality management by process control, at each step in the process, using Datamyte software and data collectors,” says the company’s Director. “This is far more efficient than managing quality by product control which focuses only on testing and controlling product at the end of the operation.

“When you have the steps of any given process under control using SPC, you don’t have to invest as much time and effort on checking the finished product because you know the process that produces it is in control,” he added. “This gives you greater confidence in your quality and frees you up to pursue other objectives.”

The company implemented a new net weight control program in order to reduce giveaway while still meeting customer requirements. Vibratory feeders are used to level out the amounts of ingredients fed into filling machines and then into containers. Net weight or fill target is achieved within a certain tolerance, based on standard deviation. The software has to be robust enough to capture multiple measurements and has to be flexible enough to adapt tolerances dynamically to accommodate different bag sizes.

Canada Rubber Group gains efficiencies with Quality Planning Studio

THE CHALLENGE:

CRGI had used Excel spreadsheets for advanced product quality planning (APQP) and production part approval process (PPAP). Using spreadsheets worked O.K. because they were flexible and easy to modify, but they had limitations and serious downsides.

“In the automotive business, using a spreadsheet for quality planning made it very difficult to control revisions, and control links between flow charts, FMEA and control plans,” says Quality Control Manager Mr. Cegielkowski. “Everything was controlled manually. The quality control process was time consuming and prone to small mistakes.”

When Cegielkowski was offered the quality manager position, he knew that if he wanted to move the company into the future, he needed to improve processes and find a better, software-based system for APQP and PPAP.

A Swiss transnational food and beverage company relies on DataMetrics globally for net content management

Today’s food and beverage manufacturers are challenged to achieve tight net content control. Under-fill your product weight, volume or count, and you violate such regulations as the Fair Packaging and Labeling Act (FPLA). Overfill, and you not only waste raw materials, but also lose thousands of dollars in profit. Yet, a wide range of issues can interfere with achieving tight net content control. These issues can stem from normal wear and tear of your production machinery to fluctuations in the raw materials used to make your products and beyond. As a quality control manager, how do you find a balance between under-filling and overfilling to drive profitability while managing compliance? How do you simultaneously optimize your food and beverage manufacturing processes to help ensure product safety, quality and satisfaction among consumers — all while upholding your company’s valuable reputation?
Balance Profitability and Compliance … and Win
The answer is DataMetrics. A Swiss transnational food and beverage company piloted the solution in one plant to reduce overfilling. When the solution proved to be successful, saving the company more than $35,000 USD in overfilling-related costs, the company multiplied their savings by rolling DataMetrics out to more than 50 locations worldwide. DataMetrics can help you gain the upper hand, too, with a unique set of features to optimize your production line to net content and weight requirements.
Ensure compliance while maximizing revenue potential.
DataMetrics gives you access to fill weights, levels and counts in near real time. This information allows you to track, analyze, identify and report on mission-critical processing data you can use to resolve issues as they happen.
Reduce scrap and rework with near real-time notification.
DataMetrics real-time event monitoring and notification ensures that everyone who needs to know about production issues, lot status and more is made aware of problems as they occur. This communication, powered by configurable alarms, puts the brakes on product problems and reduces scrap and rework.
Control costs through broad connectivity.
Get the most return out of your current investments. DataMetrics connects to more devices and systems than any other SPC program, including check-weighers, Solartron digital gages and GageWay wireless systems, as well as more than 70 device drivers. This means you can use your existing gaging and related software programs and minimize your investment in new equipment, software and training.

Are you intentionally overfilling to avoid a compliance risk?

Today’s food and beverage manufacturers are challenged to achieve tight net content control. Underfill your product weight, volume or count, and you violate such regulations as the Fair Packaging and Labeling Act (FPLA). StarKist Co., makers of StarKist®-brand shelf-stable seafood products, was sued for under-filling some of its five-ounce canned tuna products by as little as 0.03 ounces, which was in violation of state and federal law. However, if you overfill to avoid noncompliance and lawsuits, you not only waste raw materials, but also lose thousands — if not millions — of dollars in profit.

Yet, a wide range of issues can interfere with achieving tight net content control. These issues can stem from normal wear and tear of your production machinery to fluctuations in the raw materials used to make your products and beyond. As a quality control manager, how do you find a balance between under-filling and overfilling to drive profitability while managing compliance? How do you simultaneously optimize your food and beverage manufacturing processes to help ensure product safety, quality and satisfaction among consumers — all while upholding your company’s valuable reputation?

See how this error-proofing solution upholds quality, saves time and reduces costs

Quality Digest has been illuminating the path for quality professionals for more than 40 years. A weekly video podcast hosted by Quality Digest Live, demonstrated the Wireless LightStar™ Torque Wrench and 600 WiFi Data Collector from Datamyte.

This torque management solution raises the quality bar with SMARTWRENCH™ technology for precision auditing, including a patented angle restart algorithm eliminating false readings, verification of correct Nm wrench, and calibration tracking. The solution eliminates the downtime associated with reacting to false out-of-spec readings and costs associated with failed critical fasteners.

Top automotive interiors manufacturer streamlines its data collection process

THE CHALLENGE:
Datamyte partners with a top automotive interiors manufacturer who recently faced numerous complaints from their OEM customers on some of their new product launches. The company utilizes several visual and manual inspection methods across their production processes; however, the data collection process has been time-consuming and error ridden. It has also led to issues around poor product traceability in product appearance, fit and function, or in some cases, not meeting traceability requirements in general.

AGS Automotive plants reaps the benefits of their QPS Cloud solution

THE CHALLENGE:

Being a Tier 1 leader in bumper/structural modules for the North American auto industry requires access to up-to-the-minute information provided by the company’s stand alone database – no matter where employees are located when they need information. Also, the quality data management software the company used didn’t have all the new functions that employees needed.

“The biggest challenge we faced was the ability to connect to our database, both onsite and offsite,” says IT Manager Mary Banaszewski. “In addition, our previous quality data management software didn’t provide the compliance we needed to conduct critical quality audits.”

Aavid Thermal finds reliability with DataMetrics for High Mix, Low Volume production

THE CHALLENGE:

Aavid began using DataMetrics in 2014, and employees appreciated the robust system. However after two years, the program was placed on hold due to a lack of engineering resources. During this period, Aavid had no way to collect data during production for statistical process control (SPC) purposes. Process control issues were only identified when non-conforming material was discovered at final inspection which proved to be very costly.

“Discovering issues so late in the process made it difficult to make changes before a lot of scrap parts were already in the pipeline,” says Continuous Improvement Engineer Nick Chase. “This resulted in an unacceptable level of scrap and rework.”