6
Use case: digital analytics reduce error rates
in the automotive industry
AT A GLANCE
PROBLEM: 5% of car doors show
clearly visible asperity after coating
ANALYSIS:
• Irregular frequency of clearly
visible surface asperities in doors
• Door becomes uneven in precleaning
or basecoating phase
INTERPRETATION:
• Real-time, based on big data
• Delivers root causes
for process errors:
- Bulge is caused by remaining
dust/dirt particles = error in
pre-cleaning phase
- Pitting is caused by
defective clearcoat =
error in basecoating phase
TAKE COUNTERMEASURES
SOLUTION: 100% intact doors
CAR MANUFACTURING – REDUCTION OF QUALITY ISSUES WITH CAR DOORS
IN PAINT PROCESS
OUTPUT
WITHOUT
DATA
ANALYSIS
OUTPUT
WITH
DATA
ANALYSIS
SPECIFICA-
TIONS FROM
ERP SYSTEM
PROCESS DATA
Central
data cube
JIT SUPPLY
OF BLANK
DOORS
Statistical
analysis tool
PRE-
CLEANING
PRIMER &
BASECOAT
Countersteering
CLEARCOAT
OUTPUT
OUTPUT
x 950
x 50
x 1,000
x 0
QUALITY
CONTROL
ü
û
ü
ü
Date and time data Sensor data Employee data ERP/job data