Tier-1 automotive supplier eliminated rework warranty claims with MileSoft Torque Traceability + Andon
Connecting 40+ DC torque controllers and 12 assembly stations to a single traceability + visual-management spine reduced critical-fastener rework to near-zero and cut downtime response from minutes to seconds.
Outcomes
Measurable results
Headline metrics from the deployment.
The Challenge
What needed solving
- Torque controller mix from Atlas Copco, Desoutter, Stanley, and Cleco — each writing logs in its own format. No single VIN-level traceability across the line.
- When a critical-fastener rework arrived from the OEM, the team needed days of forensic log diving to figure out which station, which operator, which time-window.
- Andon was a literal stack-light + paper escalation system. Mean time to first response (MTTR-FR) was 6–9 minutes.
- IATF 16949 audits required exhaustive evidence of process control that existing systems couldn't produce in less than weeks of prep.
Our Approach
How we delivered
- Deployed MileSoft Torque Traceability as the unified controller-to-MES bridge — every fastening event tagged with VIN, station, operator, controller ID, Cp/Cpk window.
- Layered the Andon System on top: live downtime + escalation dashboards on every line, with PLC integration so machine faults page the right team in <10 seconds.
- Bolted on Material Traceability for genealogy from raw lot → sub-assembly → finished VIN — closing the loop for IATF audits.
- Phased rollout: Plant 1 in 8 weeks, Plant 2 in 6 weeks (lessons-learned compression).
The Solution
MileSoft products deployed
Modular pieces that plugged into the client's stack.
Torque Traceability
Multi-brand controller integration, VIN linking, buyoff reports, Cp/Cpk metrics — IATF 16949 ready.
ExploreAndon System
Real-time visual alerts, PLC and MES integration, live downtime dashboards, OEE tracking.
ExploreMaterial Traceability
Genealogy tracking from raw material to finished product with barcode/RFID integration.
ExploreERP
Production planning, sales orders, invoicing, and production sheets — the system of record behind the line.
ExploreStack
Technical building blocks
"We used to argue with the OEM about whether a fastener was even ours. Now every joint has a digital pedigree — VIN, torque curve, operator, timestamp. Disputes evaporated."
FAQ
Frequently Asked Questions
Common questions about this engagement and MileSoft's approach.
How does MileSoft Torque Traceability connect to multiple controller brands simultaneously?
How long does it take for an andon alert to escalate to the right person?
What is the typical IATF 16949 audit prep time after deploying MileSoft traceability?
Can MileSoft Torque Traceability run in mixed-plant environments with different PLC brands?
How does MileSoft OEE tracking differ from manually calculated OEE?
Technical Research
Want the engineering details behind these results?
Read the full research paper — architecture, computational methods, governing standards, and worked numerical examples.
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