How Quantal improved its operational processes and responsiveness

Testimonial

"Digitalization and real-time visibility help our production run more smoothly on a daily basis.”

Client

Quantal S.A., founded in 1995, is a metalworking company with more than 240 employees, specializing in the production of prototypes, and serial parts for the automotive industry, and the production and assembly of components for capital goods (Sheet Metal), exporting more than 90% of its production. In addition to these business areas, it also prints functional metal parts for various applications, with one of its pillars being innovation in technology, engineering, materials, products, and services.

Challenge

In a constantly evolving market like the automotive industry, staying competitive means embracing innovation, streamlining processes, and adapting to change. 

With an industrial park of more than 60 different machines, the organization wanted to have a standard way of monitoring the operations of all its equipment, from the most manual to the most automatic, to bring greater visibility to the teams.

In addition to this real-time data acquisition, it was important to have bidirectional communication with the ERP to be able to inform the system of active manufacturing orders on each piece of equipment and also to collect more accurate records of production times by product and order.

 In addition to the objectives mentioned above, the project focused on:

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• Improve operational performance by monitoring and analyzing the status of jobs and their respective KPIs in real-time;
• Obtain complete dashboards and reports to modernize data analysis and continuous improvement tools;
• Improve the efficiency of middle management teams by eliminating tasks that can be digitized and providing visibility into production status.

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Solution

By digitizing and centralizing data from all types of equipment, from 2D and 3D lasers to machining, bending, welding, and stamping, Quantal began to monitor its shop floor in real-time. Specific indicators were also made available to assess the performance of each section of the plant.

Challenges were overcome in capturing data due to the multiple manufacturing processes and production details, such as different types of logic for accounting for parts produced or, for example, support for cases in which multiple orders are manufactured simultaneously. 

The speed of the teams' response to what is happening on the shop floor has also been improved through the escalation of automatic alerts that notify the appropriate departments in the event of quality problems or production stoppages.

The integration of proGrow with Quantal's ERP system has enabled a precise flow of information. proGrow now feeds directly into the ERP's production data, automatically providing details such as active manufacturing orders on each machine, production times, and final quantities produced, making this process completely automated.

By adopting this holistic approach, Quantal is not only responding to current industry challenges but also preparing for a future where innovation, efficiency, and collaboration are essential pillars for success.

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Results

The benefits centered especially on the ability to carry out detailed productivity analyses and to check the status and performance of each machine, which also increased the team's ability to respond to day-to-day production challenges.

The automation of capturing, processing, and sharing information has also eliminated manual and repetitive effort on the part of the team, making room for time focused on analyzing and taking action to improve operations.

The potential gains show the solution's rapid return on investment:

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• + 2 Days - Available for production per machine/month‍
• 0,5 FTE - Potential gains in reducing administrative work.‍
• 30% - Potential reduction in team response times to quality and maintenance problems.‍
• 20% - Potential for optimizing efficiency through production monitoring and analysis.