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Case Study

Empowering Real-Time Insights and Decision-Making for a Leading Automotive Manufacturer

A compact-car OEM captured quality data manually and gave leaders no mobile access to KPIs. iRDS automated quality data capture, defect tracking and real-time KPI access.

Engagement at a glance
Client
Automotive OEM known for compact, fuel-efficient vehicles
Industry
Automotive
Solution
ITHENA Rapid Deployment Solution (iRDS)
Scope
Real-time KPI access, defect tracking, data extraction, reliability logging
Headline result
5x quicker decisions
Opportunity for impact

Three numbers quality data moved.

Results after iRDS automated the client's quality data.

3x

Faster data entry

Automated capture replaced manual quality data entry.

5x

Quicker decision-making

Leaders got live KPIs on mobile devices.

89%

Drop in data quality issues

Validated data removed most quality issues from reports.

About the client

Meet the organization and understand the context behind the transformation.

A leading automotive OEM, recognized for its compact, fuel-efficient vehicles, emphasizes innovation, design, and sustainability while advancing automotive technologies. To further modernize its operations, the client sought to modernize its operations by streamlining quality data management and enhancing real-time decision-making capabilities. By implementing ITHENA’s iRDS solution, the company significantly improved operational efficiency, reduced defects, and empowered leadership with actionable insights through real-time analytics and reporting.

In their words
ITHENA’s iRDS solution has transformed our production and quality management processes. Real-time KPI access and automated defect tracking have not only streamlined our operations but also empowered our leadership to make faster, data-driven decisions. This innovation has been pivotal in enhancing efficiency, reducing errors, and aligning with our commitment to sustainability and excellence in automotive manufacturing

-Director, Quality Operations
Key challenges faced

Quality data trapped on paper.

Quality data capture was manual, and defect alerts reached the line too late.

  • Lack of automation and digitization in quality data capture and integrated reporting
  • Inability to provide real-time KPI-MIS access for leadership teams through mobile devices
  • Lack of quick defect alerts and actionable insights on the production line to optimize short-looping
  • Absence of a centralized database for MIS with data analytics support
  • Inability to provide different levels of leadership with access to a compiled quality KPI dashboard
Our solution

How ITHENA closed the gaps.

ITHENA’s iRDS solution provided the client with:

Real-Time KPI Access

Equipped leadership with integrated, real-time KPI data, accessible anytime and anywhere, enabling timely decision-making

Defect Tracking

Enabled quick data entry and real-time status tracking for defects on the shop floor

Data Extraction

Automated data extraction from existing systems, reducing manual updates

Reliability Logging

Provided consistent tracking of growth data

Inside the console

Defects caught at the line.

An illustrative iRDS view: quality data captured at every station, with defect alerts and KPIs on leaders' phones.

irds.ithena.app/quality/line-defects
riRDS QualityKPIsDefectsReliability 3 OP
Defects/Assembly line/Last 12 weeks
Defects caught at the line and data quality issues, last 12 weeksData quality issues falling
Wk 1Wk 6Wk 12
Defects caught at the lineData quality issuesLeadership KPI views
Quality data captured digitally at every station · 09:41:07
Since iRDS went liveLive
89%Drop in data quality issues
3xFaster data entry
5xQuicker decision-making
140Stations capturing data
Defects by area this week, share
Body29%
Paint24%
Trim21%
Final assembly17%
Other9%
Defect alerts3 new
Repeat defect on trim station 7, short-loop alert sent5m
KPI dashboard opened by plant head on mobile20m
Reliability log shows rising torque variance1h
Defect resolved within the shift2h
MIS report generated automatically3h

Illustrative view. Unit names, counts, shares and activity are examples; the headline results are the client's.

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