60% increase in efficiency with digital shortage management at Plasser American.

Lack of real-time data evaluation.

The defect records during the production processes were collected in a resource-intensive and time-consuming paper-based process. These were then transferred to spreadsheets in order to obtain a detailed evaluation of the current individual defect processes.

The problem was that this was not only a time-consuming documentation process on paper, but the transmission of the data was also no longer up to date. Reports had to be created several times a day in order to analyze the current situation and intervene if necessary.

More quality awareness among employees.

With the challenge of delivering products and services of the highest quality, a solution for digital defect recording along the production process had to be introduced. On the one hand, it was necessary to optimize the workflow in the context of defect recording and rectification and, on the other hand, to anchor quality awareness in every employee.

In a further step, digital checklists were used to document the entire production process. Customers could also be integrated into the processes. Testify enabled these requirements to be met efficiently.

60 % resource savings in defect detection.

Thanks to the digital documentation in Testify, the paper-based, time-consuming recording of defects is no longer necessary. Employees are equipped with smartphones and tablets and can immediately document defects, identify the correct test object and quickly rectify deviations.

Evaluations in real time.

Instead of repeatedly collecting and evaluating process data, all data is prepared transparently in the integrated dashboards. With the help of Pareto and trend diagrams, representative predictions can be made about production processes, which in turn serve as the basis for weekly management meetings.

Improving the quality of products.

Since Testify has been in use, the quality of the machines has increased significantly. This is reflected in the fact that fewer defects have been identified per area and per work process. Overall, 24% fewer defects have been recorded since the introduction of Testify than before the tool was used.

More quality awareness among employees.

With Testify, every employee in the production chain has been given a tool to ensure quality at every stage of production and avoid defects. Testify has created a workplace where quality is lived and where every single employee does meaningful work.

Plasser American’s employees and management are committed to a common goal: delivering the highest quality in the rail maintenance products and services market in North America. The project, which began with the detection of problems in the assembly area, now extends across the entire value chain to the customer’s site thanks to the scalable features of the Testify solution. Overall, up to 60% of the time associated with rectifying defects per machine has been saved.

Now that the integration of customers into the quality process has been so successful, suppliers will also be integrated into the process in future and the final testing of components will be carried out digitally with Testify.