Poka > Case Studies > Revolutionizing Production Issues Management: A Case Study on Bosch Automotive

Revolutionizing Production Issues Management: A Case Study on Bosch Automotive

Technology Category

Functional Applications - Computerized Maintenance Management Systems (CMMS)

Applicable Industries

Automotive
Consumer Goods

Applicable Functions

Maintenance

Use Cases

Inventory Management
Supply Chain Visibility

Services

Training

About The Customer

Bosch Automotive is a division of Bosch, a global technology and service provider with over 440 locations and 260 production facilities worldwide. Bosch's business sectors include automotive, building technology, consumer goods, and more. The Bosch Automotive Charleston plant in South Carolina, which employs nearly 1,500 individuals, specializes in powertrain and e-motor parts. The plant uses a performance-based pay system and was facing challenges in communication and skills tracking before implementing the Poka platform.

The Challenge

Bosch Automotive, a division of the global technology and service provider Bosch, was facing significant communication challenges in its Charleston plant. The plant, which specializes in powertrain and e-motor parts, was using two-way radios for communication. This method was inefficient as it limited associates to reaching only one person at a time. The lack of a streamlined communication system was hindering the plant's productivity and efficiency. Additionally, the plant was about to face a new product startup, which required a rapid ramp-up from setup to full-time production to customer delivery. The plant also had a performance-based pay system, but lacked a clear way to track and showcase the skills and proficiency levels of its associates.

The Solution

Bosch Automotive implemented the Poka pilot program to improve communication within the plant. Poka’s communications module allowed the plant to track, share, and update valuable information to multiple people at once through rich media such as pictures and videos. The plant also set up Poka TVs to showcase preventative maintenance dashboards and issued Poka-connected Fitbits to process technicians for automatic notifications of maintenance requests or issue solutions. A 'war table' was created to display the Kanban boards of main production lines, highlighting new issues, calls for help, and resolved tickets. The Poka platform was also used to record and display the skills and proficiency levels of associates, providing visibility for management and flexibility for shift transfers and new assignments. The plant is now working on designing a quick and efficient onboarding process using Poka.

Operational Impact

The implementation of the Poka platform has revolutionized the way Bosch Automotive manages production issues. The platform has not only improved communication within the plant but also empowered frontline workers by giving them a voice heard throughout the organization. It has created a clear escalation route for any problems they may face. The skills matrix on Poka has also allowed workers to proactively learn on the job and showcase their proficiency levels. This granular tracking has provided visibility for management to see who is actively trying to grow their knowledge and who is out of date. The plant is now working on expanding the use of Poka to other plants around the world and designing a quick and efficient onboarding process.

Quantitative Benefit

The plant executed a rapid ramp-up for a new product startup quicker than they have ever done in over 50 years of operation.
The Poka platform allows for real-time communication to multiple people at once, significantly improving the efficiency of information sharing.
The skills matrix on Poka provides a clear record of each associate's trained and demonstrated skills, allowing for more flexibility in shift transfers and new assignments.