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Client Overview

The client is a mid-sized door manufacturer and distributor, supplying a range of custom and standardized doors to commercial and residential customers. The company prides itself on high-quality craftsmanship, but recently faced challenges in maintaining this standard due to inefficiencies in tracking and managing product defects.

The Problem

The client’s manufacturing process involved manual inspection of doors before they were dispatched to customers. Factory inspection workers identified defects such as warping, poor finish, or incorrect dimensions, but the process of capturing and tracking these defects was laborious and inefficient.

Key issues included:

• Manual Data Entry: Defects were recorded on paper or in spreadsheets, often leading to delays and inaccuracies in reporting.
• Lack of Visual Documentation: Workers had no way to include photos of the defects in their reports, making it harder for the quality control team to assess the severity of the issue or its root cause.
• Time Delays: Once defects were recorded, the reports had to be manually submitted, processed, and reviewed by a separate team, leading to significant time lags between detection and corrective action.
• Limited Insights: Because the defect data was not centralized or standardized, the company had limited visibility into recurring defects, financial losses, and inventory management issues. As a result, they couldn’t identify trends or proactively address manufacturing flaws.

This process not only caused delays in resolving defects but also led to inaccurate financial forecasts and increased product waste, negatively impacting the company’s bottom line.

The Solution

The client partnered with a RooksDM to implement a Microsoft Power Apps specifically designed for factory inspection workers. This app allowed them to capture, document, and report defects in real-time.

Key features of the solution included:

1. Real-Time Defect Capture: Using the app, inspection workers could record defects as soon as they were identified. The app allowed them to fill out relevant fields, including defect type, location on the product, and other important details, using a simple, user-friendly interface.
2. Photo Integration: The app enabled workers to take and upload photos of the defects on the spot. These images provided clarity and additional context for the quality control team, helping them quickly assess the severity of defects and determine the best corrective action.
3. Instant Submission and Review: Once the defect data was captured, it was immediately submitted to a centralized system, where the quality control and inventory teams could review it in real-time. This eliminated the need for manual data transfer and reduced delays.
4. Automated Reporting: The app automatically generated reports on defect trends, frequency, and associated financial impacts. The centralized data allowed the company to monitor patterns, identify recurring issues, and gain insights into the root causes of defects.
5. Enhanced Inventory and Financial Visibility: By tracking defect data in real time, the company could assess the impact on inventory more accurately. This provided better insight into potential losses, allowed for adjustments in production scheduling, and enabled more accurate financial forecasting.

Results

The implementation of the low-code app significantly streamlined the defect management process and resulted in several key benefits:

• Time Savings: Factory workers no longer had to spend time filling out paperwork or submitting manual reports. 
• Improved Visibility: The centralized data repository gave the management team better visibility into defects, inventory losses, and the associated financial impact. 
• Faster Response Time: The quality control team could review defects as soon as they were reported, allowing for immediate action. This reduced the time between defect identification and resolution, resulting in fewer defective products reaching customers.
• Reduction in Defects: With more comprehensive data available, the company could identify recurring defects and address their root causes. 
• Better Decision-Making: Automated reporting allowed management to make data-driven decisions about inventory control, production scheduling, and quality assurance. This improved overall operational efficiency.

Conclusion

By implementing a low-code app to capture and manage defect data, the door manufacturer was able to transform their defect management process. The solution not only saved time for factory workers but also provided the company with critical insights into product defects and financial losses. Ultimately, this led to a more efficient manufacturing process, better inventory control, and improved product quality for customers.