Plex Systems > Case Studies > Plex and IGear Enhance Quality Controls for Automotive Supplier with Vision System Integration

Plex and IGear Enhance Quality Controls for Automotive Supplier with Vision System Integration

Customer Company Size

Large Corporate

Region

America

Country

United States

Product

Plex Cloud ERP
IGear Vision System

Tech Stack

Vision System
Web Service Call
Human-Machine Interface (HMI)

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Productivity Improvements
Customer Satisfaction
Cost Savings

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)
Automation & Control - Human Machine Interface (HMI)
Application Infrastructure & Middleware - API Integration & Management

Applicable Industries

Automotive

Applicable Functions

Quality Assurance
Logistics & Transportation

Use Cases

Machine Condition Monitoring
Predictive Maintenance
Process Control & Optimization

Services

System Integration
Software Design & Engineering Services

About The Customer

NHK Spring Precision of America is a division of the Japan-based NHK Spring Company, Inc., specializing in the production of springs for automotive OEMs in North America. The company is committed to maintaining high-quality standards in its manufacturing processes and uses Plex Cloud ERP software to ensure compliance with strict production quality requirements. NHK Spring sought to enhance its shipping protocols to eliminate errors in loading springs for shipment, which could lead to costly fixes and impact its relationship with key customers. The company produces four variations of springs, each identified by a specific color, and requires precise packing to ensure compatibility with robotic assemblers at the OEM's facility.

The Challenge

NHK Spring Precision of America faced challenges in ensuring error-free packing and shipping of automotive springs to an OEM. The springs, used in the manufacturing process, required precise packing to avoid costly errors that could disrupt the OEM's production line. The company initially relied on external quality inspectors and internal personnel to double-check shipments, but this approach was costly and did not guarantee flawless results. The springs, produced in four variations, needed to be correctly identified and packed to ensure compatibility with robotic assemblers at the OEM's facility. Any error in packing could lead to production halts and damage NHK Spring's reputation.

The Solution

To address the challenges, NHK Spring engaged IGear, a technology company specializing in manufacturing excellence, to design a solution that would ensure error-free shipping. IGear developed a vision system integrated with Plex Cloud ERP to verify the correct spacing and type of springs in each shipment. The system uses a vision fixture to lock trays in place and inspect them for errors, such as incorrect paint color or misaligned labels. The vision system communicates with Plex via a Web service call to validate the setup, report production, and clear trays for shipment. This integration eliminates the need for additional quality inspectors and ensures a consistently acceptable product for customers.

Operational Impact

The vision system allows NHK Spring to store images of product shipments, providing evidence to refute any claims of errors.
The integration of the vision system with Plex Cloud ERP has eliminated the need for external quality inspectors, reducing costs and improving efficiency.
The automated reporting functionality of the Plex Cloud ERP system saves time and ensures compliance with strict manufacturing requirements.
The solution has enhanced NHK Spring's ability to meet the quality expectations of its North American automotive OEM customer.

Quantitative Benefit