SEPTEMBER 2019, ISSUE 03

OPEX NEWSLETTER
The Monthly Operational Excellence Newsletter

Is it mandatory for IATF 16949 certified organizations to audit

suppliers?
Firstly, we need to understand any organization does not involve in supplier quality for
the adherence to any standards, but to deliver highest quality to its customers.
WHAT'S INSIDE THIS ISSUE:
There are various requirements stated by various international standard bodies with
respect to supplier audits. Answer to the subject question is that it is not mandatory to
do supplier audits for all the suppliers. IATF 16949 standard states that the need & Case Study: Real-time remote
frequency of audit shall be decided based on below factors: machine monitoring system
Risk from supplier
Supplier performance Product / Features:
Supplier QMS status i.e. whether the supplier is certified to ISO 9001/IATF16949 RIYO Connect - IIoT Solutions

Organization need take systematic approach using these factors and prepare the audit
Article:
matrix for whole supplier base. There will be results in the form of audit frequency like
No audit required Learning by sharing platform for
Audit once a year because supplier falls into low risk and good performance Continuous improvement in the
section. manufacturing value chain.
Audit once in each quarter because supplier falls into high risk, low in performance.

info@opexworks.com http://www.opexworks.com +91-7498399489

 RIYO Connect
Affordable Machine To
Mobile Connectivity
The Industrial Internet of Things (IIoT) is the
technology that is transforming the
manufacturing industry. For MSMEs, IoT
offers game-changing opportunities to
enable greater control over the
manufacturing operations, real-time visibility,
and proactive approach in decision making
with the help of analytics at hand.
OpExWorks Solutions is working with
MSMEs to provide data and analytics directly
from Machine to Mobile with RIYO Connect.
It enables comprehensive monitoring of plant
activities on the mobile device, even from
remote locations. RIYO Connect is an
affordable solution to get data from any
machine to any device – mobile, tablets, or
computers. It provides real-time information
on critical aspects like·
Production
Stoppages
Losses
OEE
RIYO Connect can align MSMEs with
Industry 4.0, i.e. connected equipment,
centralized data on cloud and analytics.
Declaration:
OpEx Newsletter is the private
circulation document of
OpExWorks Solutions Private
Limited. You can write to us for
any feedback, suggestions or
queries at info@opexworks.com
or call on +91-7498399489
info@opexworks.com
CASE STUDY: MACHINE TO MOBILE CONNECTIVITY
RIYO Connect at Auto Component Manufacturer for Real-time
remote machine monitoring system
Introduction about the customer:
The leading auto component manufacturer consists of two major divisions -
Foundry and Machining with over 100+ CNC machines. They are one of India’s
largest, unique foundries at a single location with multi-location machining
units across India.
They provide fully integrated, innovative foundry and machining solutions to the
booming Agriculture - Farm Equipment, Automobile, Commercial and Passenger
Vehicles, Construction Equipment, Power and Hydraulics Industries.
The Challenge:
As a part of their Digitalization and Industry 4.0 initiative, the leading auto
component manufacturer primarily wished to leverage IoT for maximizing
operational efficiencies, productivity, reducing the energy footprints and
maximizing capacity utilization. But there were several challenges at the outset:
Firstly, they have multiple assembly lines with a diverse set of machines, all
communicating on different protocols. As such, primarily they needed a
partner who could connect diverse set of assets on to a single platform.
Lastly, they faced the typical challenge of innovating in ‘Brownfield’ markets
– wherein the real bottleneck is in integrating IoT in tandem with both the new
and legacy equipment without any further CAPEX for asset substitution.
The Solution:
OpExWorks Solutions Pvt Ltd defined their IoT integration requirements and
filled in the gap with "RIYO Connect”, a scalable cloud based Industrial IoT
Platform. “RIYO Connect” integrates with PLC of machines and capture required
data from holding registers in real-time. Multiple CNC machines were connected
to multiple PLCs which are then connected to one local system using ethernet.
The data captured in machine is then processed to the centralised OpExWorks
cloud for further analysis. This data is reflected in web portal as well as in RIYO
mobile app in a real-time.
Within a few weeks of deployment, machines and systems began streaming real
time data to RIYO Connect as a centralized platform. And the output of these
configured tags was utilized in near real-time or on a scheduled manner to
provide insights into Overall Equipment Effectiveness (OEE). In addition to this
existing machine data, HMI screen also enabled operators to log supplementary
data (such as stoppages reason codes) to further track stoppages pockets,
identify major causes and create an action plan to improve uptime & calculate
the “mean time to resolve”.
“RIYO Connect” facilitates their management with a dashboard to address top
reasons for unplanned downtime or machine failures, real-time OEE, energy
consumption, etc. Further “RIYO Connect” provides a flexible pricing model
which means that the customer only pays for machines connected on per
machine per year basis.
http://www.opexworks.com +91-7498399489
LEARNING BY SHARING PLATFORM FOR CONTINUOUS IMPROVEMENT IN THE
MANUFACTURING VALUE CHAIN.
Continuous Improvement Network from OEM Manufacturer to Tier II Suppliers.

Manufacturing companies adopt kaizen methodology as a continuous improvement strategy within the organization.
Mostly all manufacturing companies are familiar with this methodology, more so for automotive or auto component
manufacturers where it is part of their working culture.

Current Scenario

Individual organizations have successfully deployed Kaizen methodology in their working culture. Many times these
improvements are deployable in other similar processes in associated organizations for immediate results. Due to lack of
visibility of improvements done by one associated organizations to the other associated organizations, the teams
continue to face problems and losses in spite of the solutions being available. This visibility of kaizen improvements is
made simple by using Kaizen Network by OpExWorks Solutions Pvt. Ltd. Moreover, this Kaizen Network is made
available free of cost to all organizations and their associated organization or suppliers.

Sharing continuous improvements within a group of companies

Many times one business group is doing business with multiple companies. Using the kaizen network, you can easily
make kaizen improvements done by one of the units of the group visible to other units of the group for immediate
deployment in similar processes. These units can benefit from this ready to deploy improvement without reinventing the
wheel again.

In this deployment of kaizen network corporate offices can monitor continuous improvement culture within group
companies. Corporate offices can assess kaizen improvements by group companies on a predefined framework of rating
and reward the best efforts.
Sharing continuous improvements in supply chain

Monitoring kaizen improvements in the supply chain are difficult due to varying locations of these vendors. With kaizen
network, improvements done & uploaded in kaizen net are visible to other suppliers. Vendors can then choose kaizen
improvements appropriate to their processes and deploy ready to use improvements for immediate results.

In this deployment of kaizen network customers can assess the kaizen on a predefined framework of rating and reward
the best efforts of suppliers. Using this assessment framework online kaizen competition can be organized within
suppliers.

Objectives of Kaizen Network:

Encourage internal and external teams to adopt an environment of problem-solving and continuous environment.
Create a kaizen bank of all kaizen done by associated units either group companies or suppliers.
Provide a collaborative platform to showcase efforts on the continuous improvement journey.
Promote an environment of share and learn by providing teams with the knowledge base of innovative Kaizen ideas
within the groups.
Increase the potential for horizontal deployment or replication by adopting ready-to-deploy improvement ideas where
feasible.
Acknowledge the best efforts in continuous improvement by using a customizable assessment model.
Assessment of Kaizen improvements on a predefined framework for ratings. Using these rating companies can
organize online kaizen competitions within the supply chain by larger participation and simplified assessment for
rewarding best efforts.

Free for lifetime:

Kaizen network is available for deployment in your group of companies or supply chain for free for lifetime. All features
are available for free and there is NO restriction of a number of companies or vendors or users.

info@opexworks.com http://www.opexworks.com +91-7498399489