The automotive sector plays an important role in the global industrial structure. In Brazil, it represents around 22% of industrial GDP. In most cases, companies in this sector are transnational, which operate on a global scale or serve specific geographic regions, through multi-plants, which generally produce the same types and models of vehicles in different locations. Sequor Softwares Industriais is present and consolidated in this sector, count on our solutions and check out the case below!

Many printed documents are generated, such as work instructions, quality checklists and TPM.

Staff on the factory floor carry folders, where they look at their work instructions, the TPM, they have a clipboard with a printed document where they must enter what they are doing, their checklist and the quality checklist at some stations on the production line. The operator must also make some observations, evaluations of the part and then complete everything manually.

Once this is done, the documents need to be placed at the appropriate workstations, the TPM needs to be carried out, quality data is collected manually, all paper data needs to be digitized and then the documents must be archived and kept in archive files. This ends up causing a huge inconvenience as the generation of physical documents within a company is currently unfeasible.

We developed an app where work instructions are sequenced, with images in a very dynamic way. For each operation we measure in real time what is happening.

We placed buttons on the screen to facilitate some of the operator's tasks, such as stopping a treadmill, calling a leader, asking for maintenance help, reporting a missing part, etc.  These activations can be viewed on the call screen or on the red, green and yellow siren “lollipop”.

Through the system itself we have user tracking. Our client can view how the diagnosis of that station was, whether the operator's login was valid, whether the machine was in automatic or manual mode and we can diagnose the workstation, being traceable.

We also have user history, start time and end time. We have the quality checklist, where the operator has an image of the part and allows him to identify the place where he found the problem and make a note, which was previously done manually via spreadsheet and someone had to type it in.

The company decides when to carry out TPM.

We have a sequence of what needs to be done, whether it works or not, it may or may not be integrated into the maintenance system, you can check an image of what needs to be checked and check it.  It is a very effective method as the system progresses and informs you of the next check it should carry out.

This scanning will generate a daily check report on the equipment that the operator needs to carry out. With this, all the notes he makes will be filled in this report automatically.

Depending on the interaction we have with the equipment, we can even collect our own images if there are images in the field of view. Integrating with the equipment or our system, all this information can be collected through Collection, an integration with the PLC or through a tablet in the operator's hand.

Data collected in real time, less paper printed at the factory, less R$1 thousand per year, contribution to company sustainability (1 line less 1000 printed sheets), information aimed at all those responsible, less time downtime due to communication difficulties, one less employee for taking notes (R$60 thousand per year), one less employee for generating reports (R$60 thousand per year), less physical space for paper files and savings on files outside the company.

Level the variety and volume of items produced.

• Increased Equipment Availability: Reduces failures and downtime, increasing equipment availability and operating time.

• Reduction of Breakdowns and Unplanned Maintenance: With monitoring and preventive maintenance, TPM minimizes the occurrence of breakdowns and emergency interventions.

• Improved Product Quality: More reliable equipment produces fewer defects, contributing to more consistent, high-quality production.

• Increased Productivity: Reduces machine downtime, allowing greater production flow and gains in efficiency.

• Greater Safety for Employees: Well-maintained equipment presents a lower risk of accidents, ensuring a safer work environment.

• Reduced Maintenance Costs: Preventative and predictive maintenance optimizes the use of resources and reduces costs with emergency repairs and parts replacement.

• Operator Engagement: Promotes operator involvement in equipment care, increasing responsibility and a sense of ownership.

• Real-Time Information and Traceability: With the digitalized TPM, information about the status of equipment is accessible in real time, facilitating quick and effective decisions.

• Contribution to Sustainability: Fewer failures and downtime represent less waste of energy, materials and resources, contributing to a more sustainable operation.

• Process Standardization and Continuous Improvement: TPM establishes maintenance standards and encourages the constant search for improvements in the management of industrial assets.