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Morgan Computer Services, Inc.
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General Motors/Saturn, Wilmington, Delaware
Project: Inspection Operating Method (IOM)
Business Issues: At the GM/Saturn automotive assembly plant in Delaware, it was determined that the ISO 9000 related procedures for maintaining inspection operation methods was obsolete. These methods are comprised of related text, drawings, and photographic images. The current method of maintaining Excel spreadsheets for each inspection station had replaced hand-written paperwork; however, the process required continual effort to maintain and synchronize documentation as multiple individuals maintain information from many locations within the plant. Excel was being pushed beyond its capabilities in terms of spreadsheet size and time to retrieve
the needed information. In addition, the current process was labor intensive and stored redundant information. It became increasingly more important to ensure that the information used to define inspection methods was consistent, current, and efficiently utilized.
The MORGAN Solution: MORGAN developed an Intranet hosted, Web-based Inspection Operation Method application using a scalable system model that has improved production quality and productivity by eliminating outdated information, providing capability to prepare for future model year planning, and providing on-line access at the inspection station to as many images as are needed to support manufacturing of high quality products. The program architecture stores one (1) procedure with multiple criteria for each in the database and also includes table-driven parameters for each for each inspection station. This architecture permits multiple areas to print reports that contain only the criteria
needed for the station while minimizing data input requirements and ensuring the currency, accuracy, and standardization of inspections methods throughout the plant. IOM includes advanced capabilities for image selection, association, and multiple image display. In addition, it includes security and revision history capabilities to ensure quality performance in compliance with ISO 9000 standards.
Benefits: Over and above the estimated savings of nearly $100,000 per year, the Inspection Operation Method has several additional benefits including: Labor required to input, maintain, and distribute Inspection Method procedures is reduced by 80%. Management has increased control over production operations. When production problems are identified or product specifications are changed, inspection requirements can be changed and distributed to all affected operating areas simultaneously, on-line, and in real time. And, most importantly, the new system is ready for implementation at other GM / Saturn locations as designed without modification. Only data will need to be reviewed and tailored to match the process operations at other locations.
Technologies: Plant Floor Assembly Operations, ISO 9000, Intranet, Thin Client Applications, DLL
Tools: Visual Basic, Visual Interdev, MS-SQL Server, HTML, ASP, Java, & IIS
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