Unified error coding in production
The Process and Project Management Department at GIGATRONIK advises and supports customers in improving their business processes, in quality assurance and in the implementation of projects. Our goal is to help customers in the area of conflict between cost, schedules and quality to organize their work and development processes optimally, so as to ensure the quality of their work and to be able to implement IT, E/E or development projects reliably. This includes, for example, a successful fault management system, as was introduced at a southern German car manufacturer with our support.
"We help our customers organize their processes optimally, so as to ensure the quality of their work and to implement projects reliably."
Process and Project Management
Successful error management
At a southern German car manufacturer, a global structure project was set up to provide a basis for a successful fault management system at the company, which increases the efficiency of both troubleshooting and fault avoidance. An important prerequisite for this is to ensure that all participants have the same understanding of a particular fault. It was therefore an essential component of the project to define and introduce a common language, which would be spoken in all departments, such as Development, Purchasing/Parts Management, Production and Service. Within this project we have assisted our customers with the introduction of the unified error coding.
No misunderstandings: uniform error codes in all departments
The error codes are applied in a uniform language and structure and are used for detecting product-related errors in different departments and specialised processes. This error code includes respectively the damaged component of the product (e.g. the door), the matching damage type (e.g. a scratch) and fault location (e.g. far left). To create and maintain these error codes, is the responsibility of a special Editorial Department, which links together the catalogue information on a cross-department basis and acts as an interface to the user, who detects and records the error. As part of the Editorial Department, we were responsible for the Assembly Department and carried out its requirements.
"The unified error coding is a key factor in efficient troubleshooting."
Translating catalogues and setting up new systems
One of the challenges in this project was the replacement of the previous error catalogues. Previously, each department maintained its own catalogue according to its own rules. The contents of the old catalogues had to be linked and mapped to the new unified catalogue. This mapping was carried out step-by-step. Each previous term from the old catalogues has been assigned a technically apt term from the new catalogue. In addition, the challenge is to enable and adjust the relevant processes and systems in such a way as to enable access to the new catalogue.
From a pilot plant at all manufacturing plants
A new uniform catalogue in production plants was launched in a pilot plant of the car manufacturer. In a preliminary study, the plant-specific processes and IT systems mainly affected were identified and the corresponding feasibility confirmed. Experience gained from the pilot plant was consolidated in the other production plants.
Proximity to the customer is important: a look at the production plants
Correct master data requires direct proximity to the customer and to the product. For this reason, in Germany we took the opportunity to visit the different production plants, and were able to gain a good insight into the assembly processes. This puts us in the best possible position at the outset, to be able to define error codes correctly and accurately.