90%
faster root-cause analysis for production and field issues
25%
Significant reduction in manual documentation effort and errors
BACKGROUND
A packaging machine manufacturer specializing in bottle filling, capping, labeling, and end-of-line packing systems was facing challenges in tracking components, assembly activities, and quality records across multiple machine projects. Manual records and spreadsheet-based tracking made it difficult to obtain complete production history during customer audits, warranty claims, and service investigations.
CHALLENGE
- Limited visibility of component usage across machine builds
- Difficulty tracing machine history during customer complaints and field failures
- Manual documentation leading to data inconsistencies and missing records
- Lack of linkage between production, quality inspections, and machine serial numbers
- Time-consuming audit preparation and root-cause analysis
APPROACH
- Implemented Opcenter to establish end-to-end production traceability across the manufacturing process
- Digitized work order execution and machine build tracking
- Captured component-level traceability using barcode/QR code scanning
- Linked machine serial numbers with assembly, inspection, and testing records
- Recorded operator activities, process checkpoints, and quality results in real time
- Created a digital genealogy connecting components, production operations, quality checks, and final machine delivery