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SWIFT COMPONENTS

Swift Components reduces downtime and meets compliance requirements with Tulip


 * INDUSTRY
   
   Automotive & Boating


 * WEBSITE
   
   Swift




ABOUT SWIFT COMPONENTS

Swift Components is a manufacturer of acoustical and thermal attenuation
components, specifically for Tier 1 Automotive OEM Suppliers. They have
strategic partnerships with Tier 1 Suppliers with a requirement to support the
development of new products, contract manufacturing of production components,
and other assembly or prototype services. Their key customers are Honda, Toyota,
and clients in the off-road vehicle / RV market.




THE CHALLENGE

In 2020, Swift signed on a business deal with Honda. This prompted them to
follow a new set of quality standard requirements, upgrading from the ISO to
IATF. This transition would require the ability to analyze data at a more
detailed level.

However, their existing system was not sufficient enough to fit the
requirements. Swift was using pen and paper at the time for their production
logs, which meant they would have to hire someone full-time to sit down and
babysit their Excel sheets all day.

Swift needed a system that could simplify data collection and display data in a
digestible format. There were four types of data Swift needed to collect:


 1. Heat Settings — process parameters for the hydraulic presses, and other
    kinds of water jets.
 2. Productivity — who did what and when, which is necessary for tracing the
    root causes of production issues.
 3. Amount of scrap — not only as a requirement made by Honda, but to also
    understand which production line had higher incidences of certain defects.
    This allowed them to figure out whether the issue was with raw materials or
    training.
 4. Lot Traceability - tracking raw material batches related to specific
    production runs




THE SOLUTION

Swift originally started with a different data collection system where they made
custom forms and fields to automatically populate CSV files. However, when their
operations team got to turning that data into a dashboard, they realized that
they would have to employ someone full time to do that work. They then decided
to start looking for a better solution to interpret that data. That’s when they
came across Tulip, which provided both the data collection and data analytics
all in one place.



HEAT SETTINGS



Being able to easily track all details of their production has allowed Swift to
log and chart highly specific measurements on their thermocouple and hydraulic
presses. And with that dashboard, the maintenance department can identify if
there are any issues or fluctuations with the heater, identify the lifespan of a
thermocouple, or spot any device or tool that may be running off-spec.


PRODUCTIVITY



Using Tulip, the production supervisor will log how many parts need to be made
per line that day. Once shop floor workers get to their station, their interface
will automatically pull what their target is for the day, and prompt them to
enter who’s at the station, how many parts they will be making, and all their
start-up settings. And if the entered information is outside of the target
parameters, supervisors will need to approve. At the end of each shift, workers
will see a production statistics sheet which they will either verify or ask for
manual adjustments, which then also gets signed off by their supervisor.

At the end of the day, once everybody has posted their finished runs in the app,
supervisors can go through and see all the results from that day’s production
logs in one place. It serves as a snapshot of that day’s performance and as
audit data for figuring out during what shift, and which line the quality issues
are repeated.



SCRAP



Workers use a bin building app to easily log when they are finished with a bin.
This simple app not only tracks how many parts are being made per shift, but
specifically the number of total scraps per shift, the types of scraps, and by
what percentage for each type. They then share the dashboard with their clients.


> You have to think about how the data would be useful because it's not enough
> to just record it. You have to put it somewhere where you can build the
> dashboard off of it easily.
> 
> Kristen Danson, Managing Partner


THE RESULTS

Swift succeeded in satisfying the requirements of their new quality management
system — all without having to restructure their operations team. Implementing
this system with Tulip greatly reduced the burden of maintaining their data
requirement and has given the operations team better control over their data.

As an added benefit with Tulip, Swift can now track their downtime more
efficiently by cause, identify the root causes of material defects, and build
production run summaries based on real-time data. These metrics have allowed
Swift to adjust appropriate goals based on the status of its operations on a
day-to-day basis.



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