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IQS, Inc. offers these case studies to show the impact of implemented IQS software within various manufacturing industries.
This 12 minute customer video case study highlights:
- PolyOne’s quality processes before IQS (PolyOne has been an IQS customer for more than 10 years)
- How PolyOne chose IQS as their Quality Management Software vendor
- The issues PolyOne was having before IQS and how IQS continues to help
- What PolyOne finds most beneficial about using IQS software and services
- How they view IQS as their IT relationship role model
Range of accessories within the automotive industry
Challenge: Cequent identified quality as a strategic competitive initiative, and their key goal was to implement an overall quality system. They also sought to sharply improve several key metrics quickly, including reducing in-process and receiving inspections, improving accuracy and timeliness of engineering changes, reducing PPM’s, centralizing documents for manufacturing accessibility and improving shop floor communications.
Solution: Cequent implemented IQS Software to automate document management including ECNs, nonconformance and corrective actions. IQS provided Cequent with the ability to offer information from previously manual, paper-based systems accessible online, on-demand. Supplier performance information was collected and made available to key suppliers to eliminate miscommunication and speed up cycle times.
Results: Dramatic results were achieved during the six-month roll-out.
- By providing suppliers with web access to corrective actions, APQP and inspection data, incoming inspections were down 90%
- Supplier PPM’s decreased from 4200 to 369 (as the same month the previous year) and continues to decline
- ECN processing went from 15 days to 3 days, and ECN accuracy increased that year from 78% in January to 97% in July
- Scrap was reduced to 0.54%
Parker Hannifin Corporation: Cylinder Division
Motion control components for industrial, automotive, and aerospace
Challenge: Parker Hannifin wanted to reduce the administrative costs of their manual quality systems across the division.
Solution: Beginning with calibration, Parker saw the value in expanding to the fully integrated IQS System. With the full system during their triennial reassessment, they had most of the IQS modules installed, and the audit and preparation time was just a fraction of what it had been. They saw their administration costs dropping with every module implemented because it was less time an employee spent ensuring documents were correct or manuals were up-to-date. At the Ashley facility, the estimated savings per module was between $8-15K per year over previous administrative costs.
Results: Upon roll-out Parker Hannifin estimated each facility saved $8k-$15k, simply in administrative costs for each of the incremental roll out functions. They estimated this paid for the cost of software more than several times over.
Chemical, Compounding and Distribution company
Challenge: PolyOne, a leading global compounding and North American distribution company was looking for a solution to cut waste in support of cost containment programs. With an abundance of manual and duplicate processes, quality and compliance were identified as areas that could be targeted. Case in point: the cost of ISO 9001 registration was large and headquarters told their registrar that they wanted a single corporate registration to replace individual plant registrations.
Solution: PolyOne chose the IQS SaaS solution to meet all their needs. IQS enabled overnight implementation at multiple sites without adding IT resources and implementation costs to their budget. The IQS SaaS strategy also reduced long-term maintenance costs and allowed them to quickly scale usage. Further, the IQS solution that they chose was part of a larger enterprise quality solution. The plans were to extend their streamlining and savings to all quality areas from engineering, employee training, and skills management.
Results: PolyOne achieved short-term six figure savings in their audit-registration costs. They have expanded the use of IQS into non-conformance and employees skills expanding their savings. PolyOne implemented IQS across 27 plants within a very tight time frame and with minimal impact on their IT resources. They met their compliance deadline with time to spare.
MTD Products Case Study
Consumer Products: lawn and power equipment
Challenge: MTD had a large supply base and was trying to get a handle on customer RMAs caused by purchased parts. Their supplier, parts, and quality information were managed in disparate systems on a plant-by-plant basis. Supplier charge-backs were handled by filling out a 3-part RDVM form which was an inefficient system costing MTD money and had potential to damage relationships. MTD’s goal was not only to recover money from suppliers for the bad parts, but more importantly, they needed to improve the process of working with suppliers. The end-goal was to reduce — or eliminate all together — the RMAs caused by purchased parts.
Solution: The IQS Solution provided MTD with a fact-based, nonconformance management system with supplier scorecards which allowed MTD to charge back supplier-related RMA costs.
- MTD recovered $6 million in the first six months of the program: 1% of their revenue.
- All of the scorecards and metrics were easily defensible, so MTD and its suppliers focused on solving problems, not debating data.
- The improved communication led to lower nonconformance issues and better overall product delivery.
formerly Skyware Global
Satellite Terminals Manufacturer
Challenge: Mark Steele characterized the situation at Global Skyware very poignantly. After joining Global Skyware as CEO several years ago, Steele had to address many challenges, such as improving competitiveness, profitability and driving efficiency through process discipline. “At Global Skyware, the company was under-performing from a quality standpoint, a delivery/service standpoint and even had very, very poor safety performance,” Steele said.
Solution: To improve competitiveness and regain profitability, Global Skyware needed a better quality management solution than its outdated, ad hoc collection of software could provide. The end of the IQS implementation project, the Global Skyware team and IQS were able to bring Global Skyware into compliance with ISO 9001 within a single year, which by any measure of progress is an impressive feat in today’s highly dynamic, global manufacturing industry.
Results: After implementing the IQS solution, Global Skyware was able to report significant progress. In short, without IQS, Global Skyware would have had a very difficult time achieving similar results with a different solution. The Global Skyware team improved all of its key quality metrics, which included:
- First-pass yield on key processes well above 90%
- Scrap rates of less than 2%
- Rework rates of less than 3%
- On-time delivery rates above 96%
- Only two recordable safety incidents in 2014
Ultra Machining Company Case Study
Precision Manufacturing for Medical Device and Aerospace & Defense Industries
Challenge: Automation of their manual systems – With a tremendous surge in growth, UMC realized the need to upgrade their ERP system and add an integrated quality system. Requirements included the support of both Medical Device and Aerospace and Defense compliance standards in one system, which would provide a broad platform for growth tailored to meet their extensive client needs.
Solution: UMC chose Epicor Vantage for their ERP needs and Epicor Advanced Quality Management powered by IQS for their quality and compliance requirements. Since IQS quality processes support the highest standard level, UMC was able to leverage IQS across industry verticals for industry compliance requirements such as 21 CFR Part 11, AS 9100, ISO 9001, and ISO 13485 certifications.
- Reduced medical device customer audit from a half day to 2 hours.
- Quality data flows through the plant in real-time and is centralized in one system to pinpoint information more quickly.
- The document control process is automated and tied to workflow rules for more efficient processing and to drive accountability.
- Quarterly management reports are more informative and standardized across the organization fostering better business management.
Pointe Precision, Inc.
Precision milling, turning, grinding, heat treating, CMM inspection and more for automotive, aerospace, medical and oil & gas industries.
Challenge: A system would have to enable them to quickly respond to customers and solve problems faster, and support their initiative to eventually eliminate quality-based problems. The new system would need to logically connect and automate quality management data and processes, filling in any gaps their current disparate systems were not managing efficiently. Pointe Precision wanted to understand where quality issues were originating so they could better manage business from an earlier point in the production cycle. For example, if they were generating a high PPM number, Pointe Precision wanted to quickly trace that information back to the source, whether it was training-, engineering- or inspection-based, to implement better procedures and actively improve business.
Solution: Pointe Precision’s Enterprise Resource Planning (ERP) provider, Epicor Avanté pointed them to Epicor Advanced Quality Management powered by IQS. Epicor Avanté and IQS were an easy choice because both systems integrate seamlessly and are proven partners in many precision manufacturing environments.
- Pointe Precision was up and running with IQS to manage supplier and customer data within two months.
- Transferred additional disparate processes and complete 70% of their entire system cross-over in 12 months.
- Established a baseline and corresponding benchmarks to continuously measure any metric related to quality.
Contract manufacturer for the global pharmaceutical, medical device, and consumer products industries.
The company was using a mix of computer-based systems, spreadsheets, and manual reports to track and manage its business. Some database fields were text-based and thus not conducive to searching or reporting; other information such as supplier approvals was in hard copy only. Although many of the tools were computer based, there was no integration of the systems in use, making data difficult to sort through and retrieve for production, reporting, customer or audit needs.
Challenge: After establishing requirements for a solution that would manage Tapemark’s increased operational processes and procedures, it was obvious their data management system was hindering operational efficiency and did not contain the enterprise system integration, quality management capabilities, and database functionality needed. The company also wanted a system that could add value to the company in terms of continuous process improvement.
Solution: After vetting several quality management systems, Tapemark ultimately chose to implement IQS across its three manufacturing facilities due to its comprehensive quality management capabilities and ease of integration with the company’s ERP and manufacturing systems.
- Significant reduction in time required to complete CAPAs with the integrated system
- Reduction in CAPAs by over 50%
- Improved manufacturing efficiencies due to more efficient scheduling
- Time to prepare management reviews reduced by over 75%