Digitized QM with Testify enables more efficient processes for cross-site production

Digitization success story of Plasser & Theurer Linz:

When production is spread across different locations, coordinated processes and collaboration in quality management are crucial. Plasser & Theurer Linz digitized these processes, saving time of up to one worker per vehicle. A digital, production-accompanying quality control for the customer is also possible.


These testify functions are used by Plasser & Theurer Linz

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digital defect detection

Use at P & T: Employees now record defects directly on the spot via smartphone using the Testify app. Production status is immediately visible to other QM employees regardless of location, and further processes can be coordinated in a timely manner.

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automated acceptance protocols

Use at P & T: Digital defect reporting generates automated quality status reports. These are shared with the customer and thus integrate customers directly into the production-accompanying quality control.

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Analysis tool

Use at P & T: the analysis tool makes improvement potential automatically visible. It identifies recurring or frequently occurring defects in production. Each defect can be traced back to the corresponding production step in individual plants. This simplifies the cause research and accelerates improvement processes.

Initial situation at Plasser & Theurer Linz

At the main plant in Linz, the machines and test procedures have to be specially adapted for individualized customer orders. Plasser & Theurer attaches great importance to close coordination with the customer. In order to further develop the processes and make them even more efficient, the main plant decided to use Testify as a digital tool after a test phase to master the current challenges.

The challenges at the beginning:

standardization Challenge: uniform documentation and fast tuning required.

The quality inspection took place before Testify in a complex process with paper, pen and photo documentary. Differences in the level of detail of documentation and paper-based records slow down processes and collaboration, especially when different production sites are involved.

Property Check Challenge: Control requested by the customer.

For a special customer order, a production-accompanying test is requested by the customer. This requires quick updates and clear descriptions of the current state of production and the involvement of the customer in the quality acceptance process.

About Plasser & Theurer

Plasser & Theurer is the world market leader in the production of track construction machinery and related maintenance vehicles. The company is a one-stop supplier and unique in the industry, focusing on the development, production and servicing of specialty vehicles and custom-made products. Plasser & Theurer relies on constant improvement through innovation while retaining tried and tested, thus revolutionizing the offers within the industry. Currently it holds up to 2.000 patents created by this dynamic corporate philosophy.

More under: www.plassertheurer.com

Solving Challenges - Integrating Testify Step by Stept

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1. Proof of Concept in a small circle

A team from the QM department at the parent plant in Linz experimented with Testify for 3 months. Gradually, more employees were involved. In the PoC package there is a close exchange with Testify in order to adapt the service to specific requirements of Plasser & Theurer Linz and to actively receive customer feedback. Testify can be adapted to individual processes and steadily develops its services through customer feedback. This enables an individually optimized organization of the Testify (Web) App

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2. Lay the foundation - digital infrastructure

After the training workshop, Plasser & Theurer Linz equipped their employees with smartphones or tablets. Defects can now be documented digitally when inspecting the machines. The QM team used the well-tried processes and quality checks in the easy-to-use Testify (Web) app. The entirety of the individual processes is now apparent. A look at the big picture offers potential to complete fine-tuning between the individual checks, to build up categories of quality checks and to constantly improve the processes.
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3. Make cooperation more efficient

For production staff, sets of checklists and shortage categories are now available. On the basis of this, the quality checks are processed and at the same time documented in a structured manner via the Testify app. This standardizes the documentation of the acceptance tests and saves time since no single protocol has to be created manually. The automatically generated reports and lists with defects to be corrected distribute the employees independently and assign individual tasks via app. Work steps can be quickly coordinated and the current status can be seen on the smartphone for all employees in the Testify Task Cockpit.

Plasser & Theurer produces across locations. For the acceptance of the products in the factory in France, the employees now only need to take the smartphone with them to have all logs and reports at a glance.

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4. Involvement of customers

The reports and logs are shared with the customer via e-mail. In this way, customers are quickly and easily integrated with clearly structured documents about current events in production. However, this does not represent any extra work, because the reports are automatically generated as soon as the employees process the quality checks assigned to the customer product and thus note the current status.

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5. Awareness of quality

For the employees of Plasser & Theurer, Testify has become a fixed part of the work processes. "There has been more cooperation", says Ing. Peter Ruff, Head of Quality Assurance. "It's not just that handling has become extremely easy - we do not have to capture a single log by hand - but employees have also become more aware of the quality and safety of our products and are actively sharing it. That brought them together more. "
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Next steps at Plasser & Theurer

Testify has become a fixed component of quality management workflows. The next step is to audit logging with Testify. Plasser & Theurer Linz has already successfully tested the first tests and the processes for the actual audit are currently being developed. In addition, additional protocols are to be converted to completely digital processes.

Further fields of development include customer access to the Testify app, which enables real-time monitoring of the production quality inspections. This promotes the further involvement of the customers in the production processes and enables an even closer exchange and cooperation in real time.

Success Stories