In automotive manufacturing, in-plant operations managers, maintenance, and service team members know that issues often arise due to undocumented components and parts not being regularly inspected or maintained. Adding to that is the competitive pressure to provide the best level of service to in-plant auto customers as possible, from entire processing lines to the smallest of critical parts. Simultaneously, keeping tabs on the range of critical parts specified for various areas such as engine, body and assembly, paint shop, compressors, die casting, stamping or the transmission area can be a complex, time-consuming proposition, especially when it comes time to reorder. Predictive maintenance was a successful approach for a customer.
A global manufacturer of automobiles, power sports, and consumer products experienced a significant hydraulic hose failure during a third-shift operation. As a result of limited maintenance staff, the failure went unnoticed for several hours until a large oil reservoir had finally run dry.
Unfortunately for the company, this hose failure resulted in:
More than 60 gallons of hydraulic oil being spilled.
Significant cleanup expense.
Risk of fire and damage to ancillary equipment.
Longer downtime than necessary due to product identification and replacement purchasing during off-peak business hours.
The company attributed these issues to components that were undocumented and not regularly inspected or maintained.
Managing critical assets and their required maintenance can be a challenge for even the most capable automotive OEM, regardless of company size. With hundreds of thousands of individual parts or components that require maintenance, keeping detailed asset records or maintenance logs can be a burden. And, most asset management systems do not break capital assets down into the components that comprise them. One component’s failure can lead to disastrous effects throughout an entire system.
How can an automotive OEM reduce operational and employee risk and avoid downtime all together?
In the situation described above, the customer looked to our engineers to provide them with an essential asset management solution. The latest tool designed to simplify the process and reduce paperwork is digital asset tracking, which we delivered by implementing the Parker Tracking System (PTS). PTS helps customers avoid downtime with a secure, online tagging system for critical parts and components, supported by a worldwide team of Parker employees and distribution partners.
This web-based asset tracking and management system combines part serialization with tagging and a range of part-specific information so that OEMs can track, organize, and manage their use of critical parts. As a cloud-based tracking solution, users have online access to needed documents like parts lists, manuals, diagrams, certifications, and more. This results in easier tracking and management of critical parts, reduced lead time and complexity in placing an order, and enhanced service, safety, and compliance features.
Automotive OEMs using PTS stand to gain greater convenience and better oversight, because the system takes over much of the tedious parts-related paperwork that OEMs used to handle themselves, to keep the plant and operation-specific part and assembly data organized.
The PTS Pro system was deployed at the site, along with a comprehensive asset identification and preventive maintenance (PM) program administered by a Parker distributor. Asset records were converted from static spreadsheets or parts manuals to the PTS application where inspections were performed for all installed assets. A standardized PM schedule is now assigned to each asset class based on a variety of product risk factors.
The customer now receives:
detailed reports on product condition following scheduled service visits;
outsourced asset PM and replacements by highly trained and certified hydraulic technicians;
reduced risk to operations and employee safety.
PTS is both a program and a technology that Parker pioneered just over a decade ago out of a long-term focus on providing superior service, convenience, and value to supply chain partners and customers. Initially used to track and manage specifically engineered hose assemblies, PTS has expanded over the years to cover products across many Parker divisions.
Today, some 25 million assets in 62 countries and thousands of locations are being tracked and managed using PTS. Subscribers include distributors, OEMs, and end-users in the automotive, healthcare, oil and gas, food and beverage, and other market segments.
Automotive OEMs, learn from your peers -- download the in-plant automotive manufacturing case study fact sheet.
Article contributed by William Sayavich, marketing manager, Parker Global Services division.
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