Today, we are sharing a real case from LinkedData, demonstrating how lean digitalization can rapidly improve enterprise operational efficiency and reduce costs. This case took place six years ago at an automotive parts manufacturing company in Nanjing.

Click the link to watch the full case demonstration video：https://youtu.be/ytDNYJvIh5A?si=N0XsyidsPYYjZw1z 

Background: A Challenging Situation for an Automotive Parts Manufacturer

At that time, this company faced significant challenges in operations and quality. Compared to both its internal sister plants and external competitors, it was at a disadvantage. They urgently needed to improve key operational indicators in the shortest time possible to enhance their overall competitiveness. To achieve this goal, we introduced LinkedData’s lean digitalization solution and utilized the Digital Cockpit to optimize operations comprehensively.

LinkedData Digital Cockpit: Empowering Enterprises with Efficient Decision-Making

To better illustrate the situation, we used our system to demonstrate key data from six years ago. For clarity, we structured the analysis around different roles within the organization:

• Plant Manager: Responsible for plant-wide production, quality, and efficiency management.

• Global Production Director: Oversees multiple plants and sets performance targets.

• Production Supervisors & Engineers: Manage specific production lines and quality targets.

• Team Leaders & Technicians: Directly oversee 1-2 production lines, ensuring execution.

As the plant manager, the first step was to monitor the overall operational KPIs. Using the system’s tiered reporting, we focused on three key performance indicators (KPIs):

1. Scrap Rate: High scrap rates drive up quality costs and are a critical concern.

2. First-Pass Yield (FPY): Reflects product quality, directly impacting efficiency and customer satisfaction.

3. Production Output: For automated production lines, the goal is to maximize hourly and shift-based output while optimizing efficiency.

Identifying Issues Through Data Analysis

While analyzing the November 2019 data, we noticed a 3% decline in production output compared to October. To pinpoint the root cause, we examined daily production trends and identified an unusual drop on November 25.

Using the system’s tracking capabilities, we drilled down into the data:

1. Identifying Affected Production Lines

• Production Line 2 and Production Line 3 both experienced a significant shortfall on November 25.

2. Investigating Production Line 2

• Output was reduced by 16,000 units that day.

• The system flagged the TR26 process issue (pre-bending function failure) as the main cause.

• This was classified as a technical maintenance issue, leading to significant downtime.

3. Analyzing Production Line 3

• The main issue was a CO2 model change, which should have taken 30-40 minutes but ended up taking 3 hours.

• Further investigation revealed that this delay was caused by poor standard work time management during the changeover process.

The Value of Digital Optimization

Without digital tools, analyzing such issues would have required reviewing large volumes of paper records or Excel spreadsheets, making the process time-consuming and inefficient. However, with LinkedData’s Digital Cockpit, managers could quickly pinpoint problems, quantify their impact, trace root causes, and ultimately implement effective optimizations.

This case demonstrates that lean digitalization not only enhances efficiency but also enables enterprises to build a sustainable continuous improvement mechanism, ensuring that every optimization is precisely executed and continuously refined.

By leveraging digital technologies, LinkedData empowers enterprises to gain precise control over operational data, respond swiftly to anomalies, and significantly improve production efficiency and quality levels. We hope this case study inspires you as we continue advancing on the path of smart manufacturing—faster and with greater confidence!

Click the link to watch the full case demonstration video：https://youtu.be/ytDNYJvIh5A?si=N0XsyidsPYYjZw1z 

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