Reference Scenario: Commercial Vehicle Manufacturer
“What if every micro-stoppage on your assembly line showed up automatically — before they added up to hours of lost availability?”
Results
- ↑ Demonstrates how OEE tracking can surface a setup-loss pattern within a single shift
- ↑ Shows how downtime reason consolidation reduces manual supervisor reporting burden
- ↑ Illustrates how in-process SPC alerts can catch process drift before it becomes scrap
Reference scenario. This narrative illustrates how Qontiv’s modules fit a representative commercial vehicle manufacturer profile. Numbers are based on industry benchmarks, not data from a Qontiv production deployment. Real customer case studies will replace these as design partners convert.
The challenge
A mid-size commercial vehicle manufacturer had grown their production volume significantly over several years without a corresponding investment in production visibility infrastructure. Their OEE tracking was a combination of paper travellers and a shift-end spreadsheet that a senior supervisor maintained manually.
The manual process had two fundamental problems: lag and granularity. By the time a production issue showed up in the shift report, it was too late to address it in the same shift. And the granularity of “downtime” as a single line item told the team nothing about root causes.
The implementation
The team configured Qontiv in approximately 10 days — master data setup, Edge Gateway connectivity to their main assembly line (OPC-UA), and quality configuration for critical-to-fit dimensions.
Their primary goal was OEE visibility with accurate downtime reason tracking. They configured a focused list of downtime reason codes by consolidating their existing list through a workshop before going live.
Illustrative outcomes
In this scenario, the manufacturing operations team demonstrates how to:
- Identify micro-stoppages on a welding line as the top availability loss — previously invisible because each stoppage was under 2 minutes, below the threshold of what supervisors noticed and recorded.
- Use shift-by-shift changeover data to identify and address the highest-time sub-tasks.
- Catch a process drift on a critical press operation via SPC, preventing a potentially significant scrap event.
The supervisor role shifts from maintaining manual OEE spreadsheets to floor-level improvement work — the reporting runs itself.