The world of electronics and wiring for Electric Vehicles (EVs) demands perfect execution. From fabricating and assembling to inspecting and testing, producing complex wiring systems needs to be perfect every time.
As a vertically integrated manufacturer, Promark Electronics, a division of Electrical Components International, uses our Work Instruction Software to ensure they produce quality products from start to finish. And as a leading manufacturer of electronics and wire/cable harnesses with a focus on electric vehicles (EV), Promark is showing the world what smart manufacturing excellence can be through the power of digital integration.
We had the pleasure of talking with Adam Prizio, Promark’s Director of Manufacturing Operations to discuss how VKS is being used in their facility.
Since digitally transforming their operations and integrating our work instruction software, Promark has been able to consistently standardize their production flow, achieving a 10 to 15% decrease in overall defective units while also achieving an impressive 95% First Pass Yield Rate (FPY).
With these impressive stats and more, let’s dive into how Promark is leveraging our interactive work instruction platform to boost quality and achieve new levels of visual communication.
Customer Success Video
We had the privilege to visit Promark's facility in Montreal, Quebec to see firsthand how Adam and his team are utilizing VKS to accomplish their manufacturing goals, build quality into every process, and get the most out of their digital transformation.
Promark’s Vision for Work Instruction Software
With a wide range of wiring harnesses and a high requirement for traceability, Promark needed an Industry 4.0 tool that could match their determination for excellence. They needed a platform that would not only enable them to standardize their process but also continuously improve, evolve, and quickly take on new processes in an intelligent manner. At the same time, Promark needed a way to quickly bring their employees up to speed and train them effectively.
“One of the best benefits that we gained from bringing VKS digital work instructions on board is being able to document these manufacturing processes in a visual and interactive way for our existing staff.”
Adam Prizio, Promark Director of Manufacturing Operations
Adam explained that fabricating and assembling electronics as well as wire harnesses is largely a manual process. Due to the complicated nature of assembling components that span 30-40ft within high voltage applications, there is a lot of room for error.
For this reason, they decided to implement our visual work instruction software which allows them to not only standardize their processes but also capture data and boost quality control through interactive and visual features.
Notably, ECI (Electrical Components International) is a global manufacturing powerhouse with 40 facilities around the world and over 25,000 employees with top industry talent. Other ECI locations are always impressed with the level of efficiency and consistency Adam and his team at Promark are able to provide and achieve for their customers.
“We've been looked at as the center of excellence for smart manufacturing. Other ECI locations visit our facility all the time and they love what they see. They're very excited about a number of different things, including our digital work instructions. [...] We can do a lot with very little. We don't need the same amount of resources because we can leverage our digital tools.”
Adam Prizio, Promark Director of Manufacturing Operations
How Are VKS Work Instructions Used Within Promark’s Operation?
Promark’s operation is separated into three distinct phases of production.
Preparation - Assembly - Quality Inspections
In phase 1, Promark prepares the cables, wires, and connectors for the assembly process.
The prep work consists of cutting and striping the cabling while preparing many types of connectors and attaching components. In this phase, VKS is used to walk technicians through each process and make sure that all subcomponents are prepped and ready for the assembly phase.
“We have been able to ramp up quickly due to the use of our work instructions. [...] Our engineers break up the whole manufacturing process, put it into visual instructions so everyone can access it at the same time.”
Adam Prizio, Promark Director of Manufacturing Operations
Phase two of the assembly is where all the components are put together. Here, workers are crimping cables, splicing cables together, and connecting wires and cables in various configurations.
Due to the high variation of products and configurations that Promark sees, their assembly workers are given a standardized VKS Guidebook to follow. Having a smart standardization tool allows them to build every product the right way while also providing keen avenues and data insights needed for phase three of production.
Phase three of the production process is about quality inspections. However, this phase overlaps with the assembly phase to create in-process checkpoints and gather quality data in real time. By using our work instruction software, Promark is able to capture in-process data from their technicians performing the work while also facilitating smarter and more comprehensive inspections after the assembly is complete.
“We have test reports and forms built directly into the VKS Guidebooks to capture electrical measurements, dimensional checks, or anything like that. This way, we have full traceability to show what we inspected, how we inspected it, what we inspected it with, who inspected it, their qualifications, and when it was inspected.”
Adam Prizio, Promark Director of Manufacturing Operations
Within transportation and especially within EV (Electric Vehicle) manufacturing, a lot of components are considered safety critical since the vehicles have much higher voltages running through their wiring. For this reason, Promark uses VKS to standardize their process across all three stages while also gathering crucial data.
By using VKS across all three phases of their operation, Promark has been able to bring their FPY (First Pass Yield) to over 95% consistently.
Pro Tip: Did you know that you can now track FPY (First Pass Yield) within the updated Operations Insights page? Check out how you can track First Pass Yield and other advanced metrics with VKS v6.9.
Sharing Advanced Visuals and Knowledge
A major benefit of our work instruction software is its ability to present information and knowledge in a visual format. Reading text takes time and understanding it can often take longer. Studies have shown that people understand visual information like pictures and videos about 60,000 times faster than text alone.
Adam shared that Promark prides itself on being a very picture-forward facility, choosing to primarily use visuals to direct their workforce. And with a largely multicultural workforce consisting of people who have limited knowledge of English or French (the two predominant languages in their location), visuals have been an integral part of their digital work instruction strategy.
“It’s been very beneficial to be able to document that whole process, take pictures, and put it into a visual format so that it's easier for our existing staff to use. It really is the best tool we have to share any knowledge in a controlled and visual manner.”
Adam Prizio, Promark Director of Manufacturing Operations
Taking Control & Cutting Training Times In Half
While standardizing processes is critical to a smooth operation, it is also incredibly important to onboard and train workers properly and quickly. If training is ineffective, you may end up with mistakes on the shop floor. And long training times simply waste a company's time and money.
Promark was able to cut their training times in half by leveraging our work instruction software in two key ways.
- General training/classroom sessions
- On-the-job training
For instance, when a new machine is brought onto the floor or when Promark needs to onboard new employees, they’ll create general training guidebooks to facilitate the learning process. Then, workers are trained on the shop floor by using the work instruction guidebooks for the given process. This two-tiered training method enables workers to create value sooner while also showing employees the real-life aspects of the manufacturing process that they may not have seen until they actually did the job.
“VKS gives us a lot of flexibility when training new employees. We have guidebooks for just about all our training and it's completely interactive.”
Adam Prizio, Promark Director of Manufacturing Operations
Prior to VKS, machine and process knowledge was simply passed on from experienced technicians to new employees. The issue with this, as Adam remarked in our interview, is that the technicians may not know the full potential of that machine. Additionally, they could be teaching nonoptimal practices.
But now, Promark can train their employees with purpose-built guidebooks that show all the necessary information. Under this method, Promark has successfully standardized their training programs, ensuring that all employees receive the same information in the classroom and out on the shop floor.
Leveraging Continuous Improvement & Version Control
With an ever-evolving product line, Adam and his team needed a system that would allow them to make changes often while not losing information. And since Promark maintains strong relationships with their clients and suppliers, improving the process and achieving the best outcome is the standard practice for Promark.
“We use VKS to implement continuous improvements rather quickly. Most of our continuous improvement initiatives are production-focused, whether it's health and safety, quality, efficiency, ergonomics, implementing an initiative or communicating an improvement to the production staff. So any initiatives that we identify from a continuous improvement perspective are added to a VKS guidebook immediately. ”
Adam Prizio, Promark Director of Manufacturing Operations
One of the issues with paper or other digital platforms is that it's very difficult to track procedural changes and improvements. If using paper, you have to store it somewhere. If using applications like Microsoft Word or Excel, the changes are lost if you’re not saving or tracking every single process iteration.
However, VKS has a built-in version history that allows companies to track every change they’ve made and truly monitor performance after every iteration and improvement. If Promark needs to review their process before certain improvements are made, they can easily access the older guidebooks and even reinstate old processes if deemed necessary.
“Version Control within our guidebooks is huge for us. We make a lot of changes regularly. Our client designs are iterative and we make a lot of changes as we build either prototypes or the first articles. We have a lot of strong relationships and partnerships with our clients and suppliers so we work together to implement recommendations that are added to the process and guidebooks.”
Adam Prizio, Promark Director of Manufacturing Operations
Building Interactive Work Instructions
While step-by-step instructions are a powerful standardization tool, Promark required a platform that was also interactive. They needed a platform that worked alongside their employees as a team member, taking care of unique duties while also enhancing the capabilities of the workforce.
Adam shared with us that three interactive features help Promark control the process at different checkpoints throughout their operation.
Interactive Feature #1: Alerts
VKS Alerts help authors present users with new information. From safety warnings and quality checks to process improvements and part changes, the alerts feature allows manufacturers to ensure their employees always get the information they need when they need it.
For Promark, when a process is improved or a drawing is updated, Promark authors create alerts to inform operators that there’s been a change. Even if technicians have become complacent about a process, the alerts feature ensures everyone is informed.
Interactive Feature #2: Links to Engineering Drawings
Promark also links to their engineering drawings within their VKS Guidebook. This empowers users with readily accessible information at a moment's notice while also ensuring they view the most up-to-date documents. If a technician needs to review a drawing, they can simply access it directly from their work instructions.
Interactive Feature #3: Rule Engine
The VKS Rule Engine allows companies to create automatic actions based on current conditions and parameters. A rule is essentially an IF-THEN formula like the following:
If condition X occurs, then implement action Y.
Promark leverages the rule engine to ensure that the necessary steps and inspections occur before workers continue their work. At specific checkpoints within the process, operators will not be able to advance to the next step without an inspection from quality control or a signature from a supervisor.
This simple yet effective rule that is built into Promark’s VKS Guidebooks ensures that the right actions are achieved at every critical step of production. These rules also present a keen opportunity to achieve 100% traceability, ensuring that all key information is gathered correctly.
“A lot of our VKS rules are established for the whole company's well-being in terms of making sure we have the right documentation and the right process so we don't have to go chasing it afterward. It comes down to being able to guide and usher technicians ensuring they can focus on their tasks without needing to make independent decisions.”
Adam Prizio, Promark Director of Manufacturing Operations
For example, let's say Promark is building a work order of 50 units. There's a requirement from the quality control department to inspect that first unit before launching the full 50 units. In essence, Promark would rather catch issues on the first build rather than catch them after 50 units have been assembled.
Here is what the interactive process looks like in action.
- Operators follow their digital work instructions to build the first unit. The operator cannot move to the next unit before the inspector or the technician performs a quality check.
- The inspector performs a detailed and comprehensive inspection procedure using a quality form in VKS.
- After the inspection is done, the operator can begin assembling the other units.
- Periodically, the units are then inspected in batches to ensure consistent quality for the remaining units.
- All inspection data is stored in VKS for quality control and quality assurance.
Connecting Industry 4.0 Platforms
Currently, Promark is using the VKS API to push work order details directly from their ERP (Infor) into VKS. By leveraging the API, Promark can ensure that VKS and their ERP share the same work order information. This level of connectivity empowers Promark with a centralized source of knowledge. Workers can simply access their work orders from VKS without switching between systems.
Additionally, with their drive toward innovation, Promark is looking into pushing their connectivity even further in three distinct ways.
- Promark is also launching its own AI inspection platform, Konnect AI. Using the VKS API, Promark will be able to connect to their AI inspection program and seamlessly activate computer-controlled inspection equipment and processing.
- They are looking into opening up their connection with their ERP to facilitate a bi-directional flow of information. With this enhancement, data gathered in VKS such as completed quantities, cycle times, material usage, and more are shared with the ERP.
- Promark is looking into implementing smart tool processes. Using ToolConnect IoT and connected torque tools, Promark will be able to monitor and validate all tool processes in real time.
VKS Helps Promark Push Innovation Further for Their Customers
Adam and his team at Promark Electronics are a prime example of what innovative teams can achieve through digital transformation and smart manufacturing practices. Their determination is not only a source of strength for Promark, it is also a source of strength and confidence for their customers.
“There's nothing that will ever sell a manufacturing business more than the shop itself. And when a client walks into Promark and performs an audit, they look at the shop and they see an entire workforce with all our digital work instructions across the shop floor. I believe that speaks for itself. They know that with that tool, we can implement just about anything. We can have people communicating in real time with full traceability."
Adam Prizio, Promark Director of Manufacturing Operations
As the electric vehicle manufacturing industry continues to grow, we at VKS are proud to work with such a digitally forward company that leads the way toward innovation, excellence, and the future.
